Booster antenna configurations and methods

ABSTRACT

A booster antenna (BA) for a smart card comprises a card antenna (CA) component extending around a periphery of a card body (CB), a coupler coil (CC) component at a location for an antenna module (AM), and an extension antenna (EA) component contributing to the inductance of the booster antenna (BA). At least one of the components may have a pitch which is different than one or more of the other components. A method of wire embedding is also disclosed, by controlling a force and ultrasonic power applied by an embedding tool at different positions on the card body (CB).

CROSS-REFERENCE(S) TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. Ser. No. 14/173,815filed 6 Feb. 2014 (U.S. Pat. No. 9,195,932, 24 Nov. 2015), which claimspriority of (or benefit from) as a non-provisional orcontinuation-in-part (“CIP”) of the following:

CIP of U.S. Ser. No. 14/020,884 filed 8 Sep. 2013 (U.S. Pat. No.9,033,250, 19 May 2015) which claims priority (or benefit) from

-   -   nonprovisional of U.S. 61/868,089 filed 21 Aug. 2013    -   nonprovisional of U.S. 61/860,354 filed 31 Jul. 2013    -   nonprovisional of U.S. 61/841,286 filed 29 Jun. 2013    -   nonprovisional of U.S. 61/737,746 filed 15 Dec. 2012    -   nonprovisional of U.S. 61/697,825 filed 7 Sep. 2012    -   nonprovisional of U.S. 61/905,134 filed 15 Nov. 2013    -   nonprovisional of U.S. 61/914,996 filed 12 Dec. 2013

CIP of U.S. Ser. No. 13/600,140 filed 30 Aug. 2012 (U.S. Pat. No.8,991,712, 31 Mar. 2015) which claims priority (or benefit) from

-   -   U.S. 61/586,781 filed 14 Jan. 2012    -   U.S. 61/624,384 filed 15 Apr. 2012

CIP of U.S. Ser. No. 14/078,527 filed 13 Nov. 2013

CIP of U.S. Ser. No. 13/756,631 filed 2 Jan. 2013 (U.S. Pat. No.8,870,080, 28 Oct. 2014) which is a continuation of U.S. Ser. No.13/594,895 filed 27 Aug. 2012 (U.S. Pat. No. 8,789,762, 29 Jul. 2014)which claims priority (or benefit) from

-   -   U.S. 61/646,369 filed 14 May 2012    -   U.S. 61/660,668 filed 15 Jun. 2012

CIP of U.S. Ser. No. 13/931,828 filed 29 Jun. 2013 (U.S. Pat. No.8,708,240, 29 Apr. 2014) which is a continuation of U.S. Ser. No.13/205,600 filed 8 Aug. 2011 (U.S. Pat. No. 8,474,726, 2 Jul. 2013)which claims priority (or benefit) from

-   -   U.S. 61/373,269 filed 12 Aug. 2010    -   U.S. 61/384,219 filed 17 Sep. 2010    -   U.S. 61/493,448 filed 4 Jun. 2011    -   U.S. 61/493,611 filed 6 Jun. 2011

CIP of U.S. Ser. No. 13/730,811 filed 28 Dec. 2012 (U.S. Pat. No.9,165,240, 10 Oct. 2015) which is a continuation-in-part of U.S. Ser.No. 13/310,718 filed 3 Dec. 2011 (U.S. Pat. No. 8,366,009, 5 Feb. 2013)which claims priority (or benefit) from

-   -   U.S. 61/521,741 filed 9 Aug. 2011    -   U.S. 61/533,228 filed 11 Sep. 2011    -   U.S. 61/536,153 filed 19 Sep. 2011    -   U.S. Ser. No. 13/294,578 filed 11 Nov. 2011    -   U.S. 61/493,448 filed 4 Jun. 2011    -   U.S. 61/493,611 filed 6 Jun. 2011

This application is also a continuation-in-part of:

-   -   U.S. Ser. No. 14/714,290 filed 16 May 2015; and    -   U.S. Ser. No. 14/564,111 filed 9 Dec. 2014

TECHNICAL FIELD

This disclosure relates to smart cards (or other secure documents, andthe like), operating at least in a contactless mode (ISO 14443 orNFC/ISO 15693). The smart card may comprise a card body (CB), an antennamodule (AM), and a booster antenna (BA). The antenna module (AM) maycomprise an RFID (radio frequency identification) chip or chip module(either of which may be referred to as “CM”) and a module antenna (MA).The RFID chip (CM) may be mounted on a module tape (MT), typicallyhaving 6 or 8 contact pads (CP) for interfacing with a contact reader ina contact mode (ISO 7816-2). The booster antenna (BA) may comprisevarious antenna components, such as a card body antenna (CA) forcoupling with an external contactless reader, and a coupling coil (CC)for coupling with the module antenna (MA) of the antenna module (AM).

This disclosure further relates to techniques for embedding wire in asubstrate, such as a card body (CB) for a smart card (or other securedocuments, and the like), particularly to form the booster antenna (BA)and its various antenna components.

BACKGROUND

A dual interface (DI or DIF) smart card may generally comprise:

-   -   an antenna module AM,    -   a card body CB, and    -   a booster antenna BA.

The antenna module “AM” may generally comprise a “DI” RFID chip (bare,unpackaged silicon die) or chip module (a die with leadframe, carrier orthe like)—either of which may be referred to as “CM”—mounted to a moduletape “MT”. A module antenna MA may be disposed on the module tape MT forimplementing a contactless interface. Contact pads “CP” may be disposedon the module tape MT for implementing the contact interface. The moduletape MT may comprise a pattern of interconnects (conductive traces andpads) to which the chip CM and contact pads CP may be connected.

The module antenna MA may be connected, indirectly, via some of theinterconnects to the chip CM, or may be directly connected to bond padsBP on the chip CM. The module antenna MA may comprise several turns ofwire, such as 112 micron diameter insulated wire. Reference may be madeto U.S. Pat. No. 6,378,774 (2002, Toppan), for example FIGS. 12A, Bthereof.

The card body CB—which may be referred to as a substrate, or an inlaysubstrate—may generally comprise one or more layers of material such asPolyvinyl Chloride (PVC), Polycarbonate (PC), PET-G (PolyethyleneTerephtalate Glycol-modified), Copolyester (Tritan), Teslin™, syntheticpaper, paper and the like.

The card body CB may be generally rectangular, measuring approximately54 mm×86 mm (refer to ISO/IEC 7810), having a thickness of approximately300μm thick. The card body CB is typically significantly (such as 20times) larger than the antenna module AM.

The booster antenna BA may generally comprise a relatively large windingwhich may be referred to as a card antenna CA component (or portion)having a number of turns disposed in a peripheral area of the card bodyCB, and a relatively small coupler coil (or coupler antenna) CCcomponent (or portion) having a number of turns disposed at a couplingarea of the card body CB corresponding to the antenna module AM.

The card antenna CA and coupler coil CC may comprise wire mounted to(embedded in) the card body CB using an ultrasonic tool comprising asonotrode and a capillary. See, for example U.S. Pat. No. 6,698,089 andU.S. Pat. No. 6,233,818. The wire may be non-insulated, insulated, orself-bonding wire, having an exemplary diameter in the range ofapproximately 50-112 μm.

SOME PATENT REFERENCES

NL 9100347 (1992, Nedap) discloses a contactless card having thefollowing elements arranged as shown in FIG. 1; (1) geintegreerdeschakeling (integrated circuit); (2) electronische schakeling(electronic circuit); (3) transformator (transformer); (4) kernmateriaal(core material); (5) condensator (condenser); (6) primaire spoel(primary coil) and (7) antennespoel (antenna coil)

As is evident from FIG. 1 of the Nedap patent, the electronic circuit(2, comparable to the chip CM herein) is connected with a first coil (3,comparable to the module antenna MA herein). A second coil (6,comparable to the coupling coil CC herein) is connected with the mainantenna (1, comparable to the card antenna CA herein). The first coil(3, MA) is coupled with the second coil (6, CC), as aided by the corematerial (4).

U.S. Pat. No. 5,955,723 (Siemens; 1999), incorporated by referenceherein, discloses a contactless chip card. A data carrier configurationincludes a semiconductor chip. A first conductor loop is connected tothe semiconductor chip and has at least one winding and across-sectional area with approximately the dimensions of thesemiconductor chip. At least one second conductor loop has at least onewinding, a cross-sectional area with approximately the dimensions of thedata carrier configuration and a region forming a third loop withapproximately the dimensions of the first conductor loop. The third loopinductively couples the first conductor loop and the at least one secondconductor loop to one another. The first and third conductor loops aredisposed substantially concentrically. FIGS. 1 and 2 illustrate that alarge coil, that is to say a second conductor loop 3, has approximatelythe dimensions of a chip card. FIG. 1 illustrates a way of forming thesmall loop 4 of the large coil 3 without any crossovers, whereas FIG. 2illustrates a small loop 4 having a crossover. FIG. 3 shows a furtherpossible configuration of a coupling region between a small conductorloop 2 connected to a semiconductor chip 1, and a large conductor loop3. In this case, the coupling region has a meandering path, in order toobtain as long a length of the coupling region as possible.

U.S. Pat. No. 8,130,166 (Assa Abloy; 2012), incorporated by referenceherein, discloses coupling device for transponder and smart card withsuch device. A coupling device is formed by a continuous conductive pathhaving a central section and two extremity sections, the central sectionforming at least a small spiral for inductive coupling with thetransponder device, the extremities sections forming each one largespiral for inductive coupling with the reader device, wherein the smallspiral shows a larger pitch than the ones of the large spirals, andwherein the two extremities of the continuous path are loose such thatthe coupling device forms an open circuit. The pitches of the largespirals are chosen such as that the interturn stray capacitances isimportant and that the large spirals have mainly a capacitive behavior.And the pitch of the small spiral is chosen such as that the interturnstray capacitances are negligible, and that the small spiral has mainlyan inductive behavior. FIG. 3 shows an illustrative embodiment of thetransponder device and coupling device. The coupling device 10 is formedby a single conductive path having a central section and two externalsections. The central portion is formed as a small spiral 12 with alarge pitch, whereas the two external sections form a large spiral 11and 11′ with a small pitch. In fact, the spiral 11 and 11′ are twodistinct spiral physical elements, but forming a single geometricalspiral element (with a short interruption in the middle).

US 20130146671 (Infineon; 2013), incorporated by reference herein,discloses a booster antenna structure for a chip card is provided,wherein the booster antenna structure may include a booster antenna; andan additional electrically conductive structure connected to the boosterantenna. The contactless interface on the chip card can have a chip cardantenna which is contained in the chip card and connected to the chip.In order to improve the wireless communication capability, a furtherantenna can be provided in addition to the chip card module antenna,namely an amplifier antenna or booster antenna.

U.S. Pat. No. 8,474,726 (Finn; 2013), incorporated by reference herein,discloses a transponder with an antenna module having a chip module andan antenna; a booster antenna having a first antenna structure in theform of a flat coil having a number of turns, an outer end and an innerend, and a second antenna structure in the form of a flat coil having anumber of turns, an outer end and an inner end; the inner end of thesecond antenna structure connected with the outer end of the firstantenna structure. The antenna module may be positioned so that itsantenna overlaps one of the first antenna structure or the secondantenna structure. An antenna module having two additional antennastructures is disclosed. Methods of enhancing coupling are disclosed.

US 20130075477 (Finn, Ummenhofer; 2013), incorporated by referenceherein, discloses improving coupling in and to RFID smart cards. A datacarrier such as a smart card comprising an antenna module (AM) and abooster antenna (BA). The booster antenna (BA) has an outer winding (OW)and an inner winding (IW), each of which has an inner end (IE) and anouter end (OE). A coupler coil (CC) is provided, connecting the outerend (OE, b) of the outer winding (OW) and the inner end (IE, e) of theinner winding (IW). The inner end (IE, a) of the outer winding (OW) andthe outer end (OE, f) of the inner winding (IW) are left un-connected(free floating). The coupler coil (CC) may have a clockwise (CW) orcounter-clockwise (CCW) sense which is the same as or opposite to thesense (CW or CCW) of the outer and inner windings. Variousconfigurations of booster antennas (BA) are disclosed.

SUMMARY

It is a general object of the invention to provide improved techniquesfor improving coupling with RFID smart cards (as an example of securedocuments, and the like). It is a further general object of theinvention to provide an improved booster antenna (BA) for smart cards.It is a further general object of the invention to provide improvedtechniques for embedding wire in a card body (CB) of a smart card. Theseand other objects may be achieved individually or collectively byvarious embodiments of the invention disclosed herein.

The booster antenna BA may comprise a card antenna CA component, acoupler coil (or coupler antenna) CC component, and an extension antenna(or extension coil) EA component. According to some embodiments of theinvention generally, improvements to the booster antenna BA may includeone or more of:

-   -   arrangements of the card antenna CA, which may have only one        winding, or which may comprise two or more windings such as an        inner winding 1 W and an outer winding OW    -   arrangements of the coupler coil (or coupler antenna) CC, which        may comprise a loop which completely encircles a coupling area        on the card body CB associated with the antenna module AM, or        which may comprise an incomplete or open loop (or “horseshoe”)        which substantially fully but which does not completely encircle        the coupling area (and antenna module AM)

Some features disclosed herein and related to the booster antenna (BA)may include:

-   -   various configurations of an extension antenna (or extension        coil; EA), which may be connected to and extend from at least        one of the card antenna (CA) and the coupler coil (CC)    -   the extension antenna (EA) may be a “true coil” having at least        one cross-over

Some features disclosed herein and related to the booster antenna (BA)may include:

-   -   disposing the coupler coil (CC) off-center with respect to the        module antenna (MA) of the antenna module (AM) (FIG. 5A)    -   forming the coupler coil (CC) with a free end (FIG. 5B)    -   forming the coupler coil (CC) with two, side-by-side windings        which are extensions of the card antenna (CA) (FIG. 5C)    -   forming the coupler coil (CC) with two windings, each having        free ends (FIG. 5D)    -   forming a first booster antenna (BA-1) and partial coupling coil        (CC-1) in a first layer, and forming a second booster antenna        (BA-2) and partial coupling coi81 (CC-2) in a second layer (or        an opposite side of the first layer. (FIGS. 5E,F,G)

Some features disclosed herein and related to the booster antenna (BA)may include:

-   -   windings (turns) of CA, CC or EA having different        pitches/spacings    -   wire for the CA, CC or EA having different thicknesses    -   wire for the CA, CC or EA having different resistances

According to some embodiments of the invention generally, improvementsto embedding wire in a card body CB with an embedding tool comprising aultrasonic sonotrode and a capillary may include one or more of:

-   -   controlling force applied by the capillary during embedding the        wire    -   controlling power in the sonotrode during embedding the wire

According to an embodiment (example) of the invention a card body (CB)may comprise:

-   -   a surface having a surface area, an upper portion of the surface        constituting approximately half of the surface area of the card        body and a lower portion of the surface constituting a remaining        approximately half of the surface area of the card body;    -   a first area for extending around a peripheral portion of the        card body in at least the upper portion of the card body;    -   a card antenna (CA) disposed in the first area;    -   a second area located in the upper portion of the card body and        corresponding in size to an antenna module (AM);    -   a third area located in the upper portion of the card body which        is separate from the first area and the second area; and    -   an extension antenna (EA) disposed in the third area.

A coupler coil (CC) may be disposed in the second area. A portion of theextension antenna (EA) may be disposed adjacent at least 90° of thecoupler coil (CC). The coupler coil (CC) may have two ends, and may beformed as a closed loop or as an open loop.

The extension antenna (EA) contributes to the inductance of the boosterantenna (BA), and may be in the form of a coil comprising at least onecross-over. The extension antenna (EA) may be connected at one end tothe booster antenna (BA). The extension antenna (EA) has two ends. Oneend may be connected to an end of the coupler coil (CC). One end may beconnected to the card antenna (CA), or left unconnected as a free end.

According to an embodiment (example) of the invention a smart card maycomprise a card body (CB) having a booster antenna (BA) with anextension antenna (EA), and a radio frequency identification (RFID)chip, and may have a coupler coil (CC).

According to an embodiment (example) of the invention a method ofembedding a wire in a surface of a substrate may comprise:

-   -   with an embedding tool, feeding wire onto the surface of the        substrate while applying a given downward force and while        imparting an ultrasonic vibration to the embedding tool; and    -   controlling at least one of the downward force which is exerted        by the embedding tool and a power of the ultrasonic vibration        while embedding the wire in the surface of the substrate.

According to some embodiments (examples) of the invention, generally, asmart card (SC) may comprise a metallized layer, a compensating loop, orferrite in the card body (CB).

According to some embodiments (examples) of the invention, generally,booster antenna (BA) components such as card antenna (CA), coupler coil(CC) and extension antenna (EA) may be laid with senses (clockwise,counter clockwise) which are opposite from one another. When being laid,these components may be laid from an innermost turn to an outermostturn, or vice-versa.

According to some embodiments (examples) of the invention, a boosterantenna (BA) may comprise at least a card antenna (CA) componentextending around a periphery of a card body (CB) and an extensionantenna (EA) component, and may be characterized by: the extensionantenna (EA) component has a sense opposite to that from the cardantenna (CA) component. The booster antenna (BA) may further comprisinga coupler coil (CC) component. The coupler coil (CC) component may havea sense which is the same as the sense of the extension antenna (EA)component. The card antenna (CA) component may have an outer winding(OW) and an inner winding (IW). The booster antenna (BA) may beincorporated into a smart card (SC).

According to some embodiments (examples) of the invention, a boosterantenna (BA) may comprise a card antenna (CA) component; a coupler coil(CC) component; and an extension antenna (EA) component; and may becharacterized in that: at least one of the components has a sense whichis opposite one or more of the other components. At least one of thecomponents may comprise an outer winding (OW, ow) and an inner winding(1 W, iw). At least some of the components may have innermost andoutermost turns. At least one of the components may be laid from aninnermost turn to an outermost turn. At least another of the componentsmay be laid from an outermost turn to an innermost turn.

According to some embodiments (examples) of the invention, a boosterantenna (BA) may comprise a card antenna (CA) component; a coupler coil(CC) component; and at least one capacitive stub connected with at leastone of the coupler coil (CC) and card antenna (CA) components. One ofthe capacitive stubs may be connected with the card antenna (CA)component. An other of the capacitive stubs may be connected with thecoupler coil (CC) component. There may be two capacitive stubs and theymay each be formed in a flat coil pattern having a number of turns. Thetwo capacitive stubs may be substantially identical with one another

A linear actuator may be used for urging at least a portion of theembedding tool downward. A force profile may be established, anddifferent forces may be applied at different positions, during theembedding process, in a controlled manner. While controlling the force,a power of the ultrasonic vibration imparted to the embedding tool mayalso be controlled. Different downward forces may be applied by theembedding tool at different positions being embedded, and for a boosterantenna component having a plurality of turns, this may depend uponwhich of the plurality of turns is being embedded.

The invention(s) described herein may relate to industrial andcommercial industries, such RFID applications, smart cards, electronicpassports and the like.

Other objects, features and advantages of the invention(s) disclosedherein may become apparent in light of the following illustrations anddescriptions thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will be made in detail to embodiments of the disclosure,non-limiting examples of which may be illustrated in the accompanyingdrawing figures (FIGs). The figures may generally be in the form ofdiagrams. Some elements in the figures may be exaggerated, others may beomitted, for illustrative clarity. Some figures may be in the form ofdiagrams.

Although the invention is generally described in the context of variousexemplary embodiments, it should be understood that it is not intendedto limit the invention to these particular embodiments, and individualfeatures of various embodiments may be combined with one another. Anytext (legends, notes, reference numerals and the like) appearing on thedrawings are incorporated by reference herein. Some elements may bereferred to with letters (“BA”, “CA”, “CC”, “EA” and the like), ratherthan or in addition to numerals.

FIG. 1 is a cross-section of a dual-interface smart card and readers.

FIG. 1A is a top view of a card body (CB) for the smart card of FIG. 1.

FIG. 2 is a diagram of an embodiment of a booster antenna (BA) having acard antenna (CA) with an inner winding (IW) and an outer winding (OW),and a coupler coil (CC).

FIGS. 2A-2D are diagrams illustrating arrangements of a coupler coil(CC) in relation to a card antenna (CA).

FIG. 3A is a diagram illustrating a card antenna (CA), coupler coil (CC)and extension antenna (EA) components of a booster antenna (BA).

FIG. 3B is a diagram illustrating various areas of a card body CB of asmart card.

FIG. 4 is a diagram illustrating some antenna components, at least oneof which is a “true” coil having a cross-over.

FIGS. 4A-4E are diagrams illustrating embodiments of a booster antenna(BA) with card antenna CA, a coupler antenna (CC) and an extensionantenna (EA).

FIGS. 4F-4I are diagrams illustrating embodiments of a booster antenna(BA) with card antenna CA, a coupler antenna (CC) and an extensionantenna (EA).

FIG. 5A is an illustration of a booster antenna (BA) with its couplerantenna (CC) disposed slightly off-center from the module antenna (MA)of an antenna module (AM).

FIG. 5B is an illustration of a booster antenna (BA) with a coupler coil(CC) having a free end.

FIG. 5C is an illustration of a booster antenna (BA) with a coupler coil(CC) which is formed as an extension of windings of the card antenna(CA).

FIG. 5D is an illustration of a booster antenna (BA) with a coupler coil(CC) having two free ends within the coil.

FIG. 5E is a diagram illustrating a “folded” coupler coil CC.

FIGS. 5F, 5G, 5H are diagrams (5F, 5G, plan view; 5H perspective view) acomposite booster antenna having a first booster antenna (BA-1) in oneplane, such as on one side of a card body (CB) and a second boosterantenna (BA-2) in another plane, such as on an opposite side of the cardbody (CB).

FIGS. 6A,B,C,D are diagrams (plan view) of additional configurations forbooster antennas (BA), disposed primarily in the top half of the cardbody (CB).

FIG. 7 is a cross-sectional illustration of wire coil comprising 7windings embedded on a substrate of a card body (CB).

FIG. 7A is a diagram illustrating an embedding device based on acontrolled sonotrode.

FIG. 7B is a graph illustrating an example of force profile forembedding a series of consecutive turns of a booster antenna (BA) intothe substrate of a card body (CB)

FIG. 8 is a diagram illustrating a technique for bonding a wire to apad.

FIG. 9A is a schematic representation of an antenna module (AM),according to an embodiment of the invention.

FIG. 9B is a cross-sectional view diagram of the antenna module of FIG.9A.

FIG. 9C is plan view of the underside of a module tape (MT) for anantenna module (AM), showing an antenna structure (AS) having twoantenna segments (MA1, MA2).

FIG. 9D is a diagrammatic view of an antenna structure (AS).

FIG. 10A, 10B, 10C are diagrams (plan views), each showing aconfiguration of a coupler coil (CC).

FIGS. 11A-11F are diagrams (plan views), each showing a configuration ofbooster antenna (BA), and various arrangements of its components (CA,CC, EA).

FIG. 12 shows diagrammatically, and FIG. 12A shows more “realistically”,an exemplary embodiment of a booster antenna BA.

FIGS. 13A-13E illustrate an example of laying the booster antenna (BA),step-by-step.

FIG. 13F is a diagram showing an embodiment of a booster antenna.

FIGS. 14A and 14B are diagrams showing various embodiments ofcompensating loops (CL).

FIG. 14C,D, E, F are illustrations of including a metal foil (MF) in thecard body (CB).

FIG. 15 shows diagrammatically, and FIG. 15A shows more “realistically”,an exemplary embodiment of a booster antenna (BA) having capacitiveextensions (CE).

FIG. 15B is a diagram showing a configuration of a booster antenna (BA).

FIG. 15C is a diagram showing a configuration for components of abooster antenna (BA)

FIG. 15D is a diagram showing a configuration for components of abooster antenna (BA)

DETAILED DESCRIPTION

Various embodiments will be described to illustrate teachings of theinvention(s), and should be construed as illustrative rather thanlimiting. Any dimensions and materials or processes set forth hereinshould be considered to be approximate and exemplary, unless otherwiseindicated.

In the main hereinafter, RFID cards, electronic tags and securedocuments in the form of pure contactless cards, dual interface cards,phone tags, electronic passports, national identity cards and electronicdriver licenses may be discussed as exemplary of various features andembodiments of the invention(s) disclosed herein. As will be evident,many features and embodiments may be applicable to (readily incorporatedin) other forms of smart cards, such as EMV payment cards, metalcomposite cards, metal hybrid cards, metal foil cards, access controlcards and secure credential documents. As used herein, any one of theterms “transponder”, “tag”, “smart card”, “data carrier” and the like,may be interpreted to refer to any other of the devices similar theretowhich operate under ISO 14443 or similar RFID standard. The followingstandards are incorporated in their entirety by reference herein:

-   -   ISO/IEC 14443 (Identification cards—Contactless integrated        circuit cards—Proximity cards) is an international standard that        defines proximity cards used for identification, and the        transmission protocols for communicating with it.    -   ISO/IEC 7816 is an international standard related to electronic        identification cards with contacts, especially smart cards.    -   EMV standards define the interaction at the physical,        electrical, data and application levels between IC cards and IC        card processing devices for financial transactions. There are        standards based on ISO/IEC 7816 for contact cards, and standards        based on ISO/IEC 14443 for contactless cards.

A typical data carrier described herein may comprise

-   -   (i) an antenna module (AM) having an RFID chip (CM; or chip        module) and a module antenna (MA),    -   (ii) a card body (CB) and    -   (iii) a booster antenna (BA) with coupler coil (CC) disposed on        the card body (CB) to enhance coupling between the module        antenna (MA) and the antenna of an external RFID “reader”.

When “chip module” is referred to herein, it should be taken to include“chip”, and vice versa, unless explicitly otherwise stated.

The module antenna (MA) may comprise a coil of wire, conductive tracesetched or printed on a module tape (MT) or antenna substrate (AS) forthe antenna module (AM), or may be incorporated directly on the chipitself.

Throughout the various embodiments disclosed herein, unless specificallynoted otherwise (in other words, unless excluded), the element referredto as “CM” will most appropriately be a bare integrated circuit (IC) die(or RFID chip), rather than a chip module (a die with a carrier). Incontrast therewith, some figures present examples that are specifically“chip modules” having IC chips (such as a “CM”) mounted and connected tosubstrates. A “chip module” (die and carrier) with a module antenna (MA)mounted and connected thereto may be referred to as an antenna module(AM).

The booster antenna (BA) with coupler coil (CC) may be formed byembedding wire in an inlay substrate or card body (CB). However, itshould be understood that the antenna may be formed using processesother than by embedding wire in a substrate, such as additive orsubtractive processes such as printed antenna structures, coil windingtechniques (such as disclosed in U.S. Pat. No. 6,295,720), antennastructures formed on a separate antenna substrate and transferred to theinlay substrate (or layer thereof), antenna structures etched (includinglaser etching) from a conductive layer on the substrate, structurednanowire networks (including laser ablation) on the substrate,conductive material deposited on the substrate or in channels formed inthe substrate, or the like. When “inlay substrate” is referred toherein, it should be taken to include “card body”, and vice versa, aswell as any other substrate for a secure document, unless explicitlyotherwise stated.

The descriptions that follow are mostly in the context of dual interface(DI, DIF) smart cards, and relate mostly to the contactless operationthereof. Many of the teachings set forth herein may be applicable toelectronic passports and the like having only a contactless mode ofoperation. Generally, any dimensions set forth herein are approximate,and materials set forth herein are intended to be exemplary.

FIGS. 1 and 1A illustrate a smart card (SC) 100 in cross-section, alongwith a contact reader and a contactless reader. The antenna module AMmay comprise a module tape (MT) 110, an RFID chip (CM) 112 disposed onone side of the module tape MT along with a module antenna (MA) 114 andcontact pads (CP) 116 disposed on the other side of the module tape MTfor interfacing with an external contact reader. The card body (CB) 120comprises a substrate which may have a recess (R) 122 extending into oneside thereof for receiving the antenna module AM. (The recess R may bestepped—such as wider at the surface of the card body CB—to accommodatethe profile of the antenna module AM.) The booster antenna (BA) 130 maycomprise turns (or traces) of wire (or other conductor) embedded in (ordisposed on) the card body CB, and may comprise a number of componentssuch as (i) a card antenna (CA) component 132 and (ii) a coupler coil(CC) component 134.

The card body (CB) 120 has a surface with an overall surface area, suchas approximately 54 mm×86 mm˜=4600 mm². An upper portion 120 a of thecard body CB may constitute approximately half (such as 50-70%) of theoverall surface area of the card body CB, and a lower portion 120 b ofthe card body CB may constitute a remaining approximately half (such as30-50%) of the overall surface area of the card body CB.

A “peripheral” area 142 of the surface of the card body CB extendsaround the periphery of the card body CB in at least the upper portion120 a thereof, and may have a width of up to approximately 5 mm. Thecard antenna CA component may be disposed in this first area. The widthof the first, peripheral area 142 may be greatest at the top edge of thecard body CB, of medium width at the side edges of the card body CB, andleast at the bottom edge of the card body CB.

A “coupling” area 144 of the surface of the card body CB is located inan interior area (within the peripheral area 142) of the card body CB,in the upper portion 120 a thereof, at a position corresponding to thelocation of the antenna module AM, and may be of approximately the samesize as the antenna module AM, such as approximately 8.2 mm×10.8 mm fora 6-contact module and 11.8 mm×13 mm for an 8-contact module.

An “embossing” area 146 of the surface of the card body CB is located inan interior area (within the peripheral area 142) of the card body CB,in the lower portion 120 b thereof, is separate from the peripheral area142 and the coupling area 144, and may constitute most (such as 80-90%)of the lower portion 120 b of the card body CB.

A “remaining” (or “residual”) area 148 of the surface of the card bodyCB is located in an interior area (within the peripheral area 142) ofthe card body CB, in the upper portion 120 a thereof, is separate fromthe peripheral area 142 and the coupling area 144, and may constitutemost (such as 60-80%) of the upper portion 120 b of the card body CB.The card antenna 132 and coupler coil 134 are not disposed in thisremaining area 148—in other words, are disposed substantially entirelyin areas (142, 144) other than the remaining area 148 (and other thanthe embossing area 146).

As described in greater detail hereinbelow, according to an aspect ofthe invention, generally, an additional booster antenna component,referred to herein as an antenna extension (EA) component, may bedisposed in remaining (or residual) area 148 of the surface of the cardbody CB. The antenna extension EA may comprise several turns (or traces)of wire (or other conductive material), and may be either (i) connectedwith one or both of the card antenna CA and coupler coil CC or (ii) notconnected with either of the card antenna CA and coupler coil CC.

It is generally not desirable, but nevertheless possible that some ofthe booster antenna BA components, particularly at least a portion ofthe card antenna CA and a portion of the extension antenna EA may extendinto the embossing area (146). In such a scenario, flat ribbon wire maybe used. A wire for the booster antenna BA may be pre-flattened in anarea which will correspond to where the wire will be disposed in theembossing area (146).

An Example of a Booster Antenna (BA)

The aforementioned US 20130075477, incorporated by reference herein,discloses a booster antenna BA arrangement (configuration) for a smartcard. The booster antenna BA generally comprises a card antenna CA and acoupler coil.

A card antenna CA may comprise a single wire (or conductive trace)having two ends, arranged in a generally a rectangular spiral pattern,and disposed in the peripheral area (see 142, FIG. 1A) of the card bodyCB. The card antenna CA may comprise different portions, such asdisclosed in U.S. Pat. No. 8,130,166 (Assa Abloy; 2012). The cardantenna CA may comprise two distinct windings, such as an inner windingIW and an outer winding OW. A coupler coil CC may or may not beassociated with the card antenna CA. The card antenna CA and couplercoil CC may constitute two components of a booster antenna BA.

According to an aspect of the invention, a component, referred to hereinas an antenna extension EA may be associated with the booster antennaBA, and may be used with any suitable configuration of card antenna CAand coupler coil CC.

FIG. 2 shows a booster antenna BA comprising a card antenna CA componentextending around the peripheral area (142) of a card body CB, and havingtwo windings—an outer winding OW and an inner winding IW, both extendingsubstantially around the peripheral area (142) of the card body CB.Additionally, a coupler coil CC is shown which may be disposed in thecoupling area (144).

The booster antenna BA may be formed using insulated, discrete copperwire disposed (such as ultrasonically bonded) around (inside of) theperimeter (periphery) of a card body CB (or inlay substrate, or datacarrier substrate, such as formed of thermoplastic). The booster antennaBA comprises an outer winding OW (or coil, D) and an inner winding IW(or coil, D), and further comprises a coupler coil CC, all of which,although “ends” of these various coil elements are described, may beformed from one continuous length of wire (such as 80μm self-bondingwire) which may be laid upon or embedded in the card body CB. Moreparticularly,

The outer winding OW may be a long wire (or conductive trace) wirehaving two ends—an inner end “a” and an outer end “b”—mounted to thecard body CB in the form of a rectangular spiral having a number of (atleast one) turns, and may be disposed in the peripheral area (142) ofthe card body CB.

The outer winding OW (compare D, FIG. 1A) may be formed as a spiralhaving a number (such as 2-3) of turns and having an inner end IE atpoint “a” and an outer end OE at point “b”. The outer winding OW is near(substantially at) the periphery (perimeter) of the card body CB. Theinner end IE (“a”) of the outer winding OW is a free end.

The dimensions of the card body CB may be approximately 54 mm×86 mm. Theouter dimension of the outer winding OW of the booster antenna BA may beapproximately 80×50 mm. The wire for forming the booster antenna BA mayhaving a diameter (d) of approximately 100 μm (including, but notlimited to 80 mm, 112μm, 125μm).

The inner winding IW may be a long wire (or conductive trace) having twoends—an inner end “e” and an outer end “f”—mounted to the card body inthe form of a rectangular spiral having a number (at least one) ofturns, and may be disposed in the peripheral area (142) of the card bodyCB. The inner winding IW may be disposed within (towards the interior ofthe card body CB) the outer winding OW.

The outer end “b” of the outer winding OW may be connected with theinner end “e” of the inner winding IW, either directly (not shown, seeFIG. 2A of U.S. Ser. No. 13/600,140) or via the intermediary of acoupler coil CC.

The inner end IE (a) of the outer winding OW and the outer end OE (f) ofthe inner winding IW may be left unconnected, as “free ends”.

The overall booster antenna BA comprising outer winding OW, coupler coilCC and inner winding IE is an open circuit, and may be referred to as a“quasi-dipole”—the outer winding OW constituting one pole of the dipole,the inner winding IW constituting the other pole of the dipole—centerfed by the coupler coil CC.

The coupler coil CC may be a long wire (or conductive trace) orconductive trace having two ends “c” and “d”. The aforementioned U.S.Ser. No. 13/600,140 (US 20130075477), incorporated by reference hereindiscloses various configurations for laying and connecting the innerwinding IW, outer winding OW and coupler coil CC. See, for example,FIGS. 3A-3D therein. The present invention is not limited to anyparticular one(s) of these configurations.

The coupler coil CC may be formed as a spiral having a number (such asapproximately 10) of turns and having two ends “c” and “d”. The end “c”may be an outer end OE or an inner end IE, the end “d” may be an innerend IE or an outer end OE, as described with respect to the embodimentsshown in FIGS. 3A, 3B, 3C, 3D of US 20130075477. The coupler coil CC isdisposed at an interior portion of the card body CB, away from theperiphery, and is shown only generally with a few dashed lines in FIG.2.

It should be understood that the booster antenna BA could be made withother than wire using additive processes such as printing conductivematerial onto the substrate CB, or subtractive processes such as etchingconductive material away from the substrate CB. For such non-wireantennas, although there may be no actual direction such as is inherentwith laying or embedding the wire (the course of laying the wire, fromone end to the other), but the resulting spiral elements OW, IW, CC ofthe booster antenna BA may nevertheless exhibit a clockwise CW orcounter-clockwise CCW “virtual sense” (or orientation) which can bedetermined by analogy to laying wire. (For an additive process such asinkjet printing, which is sequential, the sense would be actual.) The“sense” can be determined by following the pattern from “a” to “f”, orfrom “f” to “a”.

As used herein, “pitch” may refer to the average distance,center-to-center (c-c), between adjacent turns of a wire for a winding(OW, IW) or the coupler coil (CC), as it is being laid. (Or, by analogy,to the center-to-center distance between adjacent conductive tracks madeby additive or subtractive processes). It should be understood thatduring manufacturing (including as a result of subsequent manufacturingsteps such as laminating), the pitch of the wire may vary or changesomewhat, such as +/−5%, or more. And, when going around a corner, suchas in a rectangular spiral, the pitch may be somewhat indeterminate. Itshould also be understood that the pitch of the windings (OW, IW) orcoupler coil (CC) may be advertently altered (typically increased)locally, such as at the free ends “a” and “f”, to accommodatemanufacturing processes (such as starting and ending embedding the wire)and the like. “Pitch” may refer to the initial (during laying) or final(after laminating) distance (c-c) between adjacent turns of a winding.

The outer winding OW, coupler coil CC and inner winding IW may be formedas one continuous structure, using conventional wire embeddingtechniques. It should be understood that references to the coupler coilCC being connected to ends of the outer winding (OW) and inner winding(IW) should not be construed to imply that coupler coil CC is a separateentity having ends. Rather, in the context of forming one continuousstructure of outer winding OW, coupler coil CC and inner winding IW,“ends” may be interpreted to mean positions corresponding to whatotherwise would be actual ends—the term “connected to” being interpretedas “contiguous with” in this context.

The inner winding IW may be disposed within the outer winding OW, asillustrated, on a given surface of the card body CB (or layer of amulti-layer inlay substrate). Alternatively, these two windings of thebooster antenna BA may be disposed on opposite surfaces of the card bodyCB or on two different layers of the card body CB (see FIGS. 5F, 5G),substantially aligned with one another (in which case they would be“top” and “bottom” windings rather than “outer” and “inner” windings.The two windings of the booster antenna BA may be coupled in closeproximity so that voltages induced in them may have opposite phase fromone another. The coupler coil CC may be on the same surface of the cardbody CB as the outer and inner windings.

The turns of the outer winding OW and inner winding IW of the boosterantenna BA may be at a pitch of 0.2 mm (200μm), resulting in a space ofapproximately one wire diameter between adjacent turns of the outerwinding OW or inner winding IW. The pitch of the turns of the couplercoil CC may be substantially the same as or less than (stated otherwise,not greater than) the pitch of turns of at least one of the outerwinding OW and inner winding IW—for example 0.15 mm (150 μm), resultingin space smaller than one wire diameter between adjacent turns of thecoupler coil (CC). Self-bonding copper wire may be used for the boosterantenna BA. The pitch of both the outer/inner windings OW/IW and thecoupler coil CC may both be approximately 2× (twice) the diameter of thewire (or width of the conductive traces or tracks), resulting in aspacing between adjacent turns of the spiral(s) on the order of 1 wirediameter (or trace width). The pitches of the outer winding OW and theinner winding IW may be substantially the same as one another, or theymay be different than each other. The outer winding OW and inner windingIW may have the same sense (clockwise CW or counter-clockwise CCW) aseach other.

It is within the scope of the invention that more turns of wire for thecoupler coil CC can be accommodated in a given area—for example, bylaying two “courses” of wire, one atop the other (with an insulatingfilm therebetween, if necessary), in a laser-ablated trench defining thearea for the turns of the coupler coil CC.

In FIG. 2, the coupler coil CC is shown without detail, represented by afew dashed lines. Some details of its construction, and how is my beconnected with the outer winding OW and inner winding IW are set forthin FIGS. 3A-3D.

FIG. 2A shows one example of a coupler coil CC component which may belaid by starting at a point “c” (coming from an outer winding OW of thecard antenna CA), laying the coupler coil CC component from an outermostturn to an innermost turn thereof, in a counter-clockwise CCW direction.When the innermost winding of the coupler coil CC component is complete(point “d”), the wire may cross-over the already laid turns of thecoupler coil CC component to resume (or continue) formation of the cardantenna CA component (such as the inner winding IW thereof), by way ofexample. Some alternatives may include:

-   -   (i) winding in a clockwise CW direction,    -   (ii) laying the innermost turn and working outward to the        outermost turn,    -   (iii) laying only a portion of the coupler coil CC component        (such as an inner winding iw thereof), exiting and laying at        least a portion of another booster antenna BA component, and        later returning to lay a remaining portion of the coupler coil        CC component.

FIG. 2B shows an example of a coupler coil CC component which may belaid by starting at a point “c” (coming from an outer winding OW of thecard antenna CA), laying the coupler coil CC component from an outermostturn to an innermost turn thereof, in a clockwise CW direction. When theinnermost winding of the coupler coil CC component is complete (point“d”), the wire may cross-over the already laid turns of the coupler coilCC component to resume (or continue) formation of the card antenna CAcomponent (such as the inner winding 1 W thereof), by way of example.

FIG. 2C shows an example of a coupler coil CC component which may belaid by starting at a point “c” (coming from an outer winding OW of thecard antenna CA), laying the coupler coil CC component from an innermostturn to an outermost turn thereof, in a clockwise CW direction. (Thismay require several cross-overs, as illustrated.) When the outermostwinding of the coupler coil CC component is complete (point “d”), thewire may be routed (no cross-over may be required) towards the peripheryof the card body CB to resume (or continue) formation of the cardantenna CA component (such as the inner winding 1 W thereof), by way ofexample.

FIG. 2D shows an example of a coupler coil CC component which may belaid by starting at a point “c” (coming from an outer winding OW of thecard antenna CA), laying the coupler coil CC component from an innermostturn to an outermost turn thereof, in a counter-clockwise CCW direction.When the outermost winding of the coupler coil CC component is complete(point “d”), the wire may be routed (no cross-over may be required)towards the periphery of the card body CB to resume (or continue)formation of the card antenna CA component (such as the inner winding 1W thereof), by way of example.

An antenna module AM may be mounted in on the card body CB so that itsmodule antenna MA is closely adjacent the coupler coil CC, for couplingtherewith. The antenna module AM may be disposed with its module antennaMA overlapping the coupler coil CC, or with its module antennacompletely within the interior of the coupler coil CC, or with entirelywithin the coupler coil CC. The antenna module AM may be installed in amilled cavity on the card body CB so that its module antenna MA may besubstantially coplanar with the coupler coil CC. The module antenna MAmay be at a different level than (not coplanar with) the coupler coilCC.

The module antenna MA for the antenna module AM may also be a coil ofwire wound with either a clockwise (CW) or counter-clockwise (CCW)sense. The module antenna MA may have the same sense (CW, or CCW) as thecoupler coil CC. The module antenna MA may have the opposite sense (CW,or CCW) as the coupler coil CC. The module antenna MA may have the samesense (CW, or CCW) as the outer winding OW and/or the inner winding IW.The module antenna MA may have the opposite sense (CW, or CCW) as theouter winding OW and inner winding IW.

It may be noted that NL 9100347 (NEDAP; 1992) and U.S. Pat. No.5,955,723 (Siemens; 1999) both describe 2 coils that are of a “givendimension”. For example Coils 1 & 3—Coil 1 on the chip and Coil 3 on thecard—and they also say they are concentric to each other and that allowsthe coupling. In the arrangements described herein, the coils (MA, CC)are not restricted to being the same size, nor are they restricted tobeing concentrically positioned.

In the course of laying the wire (or otherwise creating conductive pathsfor the antenna elements OW, CC, IW, using any of a variety of additiveor subtractive processes) for the booster antenna BA, it is evident thatthe wire (or conductive path) may need to cross over itself at severalpositions. For a booster antenna BA comprising wire, the wire may beinsulated, typically self-bonding wire. For conductive paths,appropriate insulating or passivation layers or films may be used tofacilitate cross-overs.

Booster Antenna (BA) Components and Placement on the Card Body (CB)

FIG. 3A shows, schematically, some components of an exemplary boosterantenna (BA)—namely:

-   -   an exemplary card antenna CA may comprise a first winding OW        having two ends “a” and “b” and a second winding IW having two        ends “e” and “f”, such as may have been described above.    -   an exemplary coupler coil CC may have two ends “c” and “d”, such        as may have been described above    -   the card antenna CA and coupler coil CC may be connected with        one another in any suitable manner, such as may have been        described above    -   an antenna extension AE may be a long wire (or conductive trace)        wire having two ends “g” and “h”—mounted to the card body CB in        any suitable form such as (but not limited to) a spiral having a        number of (at least one) turns, and may be disposed in the        residual area (see 148, FIG. 1A) of the card body CB.    -   the booster antenna BA components CA (OW, IW), CC and AE are        illustrated as straight line segments, the dots at their two        ends simply indicating an end position of the wire (or        conductive trace), being included for graphic clarity.

FIG. 3B expands upon FIG. 1A and illustrates, schematically andgenerally, the addition (inclusion) of an extension antenna EA componentof a booster antenna BA disposed in the residual area (148) of a smartcard. The extension antenna EA is shown only generally in this figure,it is shown in greater detail in other figures.

Some Configurations of Booster Antennas BA with Extension Antennas EA

Some configurations of booster antennas BA comprise card antennas CAwhich may be one winding or two windings (such as inner winding IW andouter winding OW), coupler coils CC (or coupler antennas) and extensionantennas EA (or antenna extension, or extension coil, or extensionloop). Each of the (CA, OW, IW, CC, EA) booster antenna componentstypically has two ends (see FIG. 3A), and typically has a plurality ofwindings (or turns). Both of the ends of a given antenna component maybe connected to ends of other antenna components. Alternatively, one ofthe two ends of an antenna component may be a free end. Some of thesecomponents may be in the form of an open loop coil or a closed coil. Anantenna component in the form of a “true” coil will exhibit a cross-over(see FIG. 4).

FIG. 4 is a diagram illustrating schematically some antenna componentsof a booster antenna (BA), at least one of which is a “true” coil havinga cross-over. Generally, geometrically speaking, if a coil has at leastone complete 360° turn, and is connected to another component that isdisposed either outside of or inside of the coil—and there are no viasthrough the substrate (card body CB) for making connections from insidethe coil to the outside thereof—it is inherently necessary that thepattern of the coil cross-over itself so that the two ends of the coilcan connect with two terminals of the other component, as shown. In thisfigure, both of the components are true-coils. As used herein, a “true”coil may be defined as a coil, loop or spiral of wire (or otherconductor) having two ends (such as “g” and “h”), extending at leastapproximately 360°, substantially enclosing an area (such as thecoupling area 144), and crossing over itself (either from the outsidein, or from the inside out).

U.S. 61/697,825 filed 7 Sep. 2012 discloses (FIG. 5H therein) a boosterantenna BA comprising an inner winding IW and an outer winding OW (asdisclosed herein, together the inner winding IW and outer winding OW mayconstitute a card antenna CA), an “open loop” coupler coil CC at theposition of the antenna module AM, and an “extension” which may bereferred to herein as an “antenna extension” or “extension antenna” or“extension coil” EA. See also U.S. Ser. No. 13/600,140 filed 30 Aug.2012 (now US 20130075477 published Mar. 28, 2013, incorporated byreference herein.

FIG. 4A is a diagram corresponding to FIG. 5H of U.S. Ser. No.13/600,140, showing a booster antenna (BA) having a card antenna CA, acoupler coil CC and an extension antenna (EA). These components may beformed (embedded in the card body CB) as one continuous embedded coil.The coupler coil CC is in the form of an open loop (“horseshoe”).

Note that both of the outer winding OW and inner winding IW are enlargedto form the coupler coil CC and substantially fully encircle the antennamodule AM in the coupling area (144). The free ends (a, f) of the cardantenna CA are shown disposed at the right edge of the card body CB.

The extension antenna EA has one end extending from an end of thecoupler coil CC, and another end extending from an end of the cardantenna CA, and exhibits a cross-over. The extension antenna EA (orextension coil, or extension loop) is disposed so as to have a portionadjacent two sides (or approximately 180°) of the coupler coil CC.

An antenna extension EA component is shown as an “extension” of theinner winding IW, comprising some turns of wire in a spiral patterndisposed near the antenna module AM in the left hand side of the top (asviewed) portion (120 a) of the card body CB. The extension antenna EAmay be disposed outside of, but near the coupling area (144) of the cardbody CB, in the residual area (148).

In this example, the coupler coil CC component of the booster antenna BAdoes not need to be a “true” coil, it does not need to have across-over. Rather, it may be a horseshoe-shaped “open” loop whichsubstantially fully, but less than 360°, encircles the coupling area(144) for inductive coupling with the module antenna MA of the antennamodule AM.

In this example, the card antenna CA is a true coil, in the form of aspiral extending around the peripheral area (142) of the card body CB,and exhibits a cross-over.

The extension antenna (or extension coil) EA has two ends—one end isconnected to the coupler coil CC, the other end is connected to the cardantenna CA. The extension antenna EA may be formed as a spiral of wireembedded in the card body CB, contiguous with one or more of the cardantenna CA and coupler coil CC, and is a true coil which exhibits across-over, and contributes to the inductive coupling of the boosterantenna BA. The extension antenna EA may be disposed in the residualarea (148) of the card body CB, and is shown as being disposed only inthe upper half (120 a) of the card body CB, but it may extend to thelower half (120 b) of the card body CB, including any or all of adjacentto, above, below or into the embossing area (146).

FIG. 4B is a diagram showing a booster antenna BA having a card antennaCA, a coupler coil CC and an extension antenna EA. These components maybe formed (embedded in the card body CB) as one continuous embeddedcoil. The coupler coil CC is in the form of a closed loop, having across-over.

The extension antenna EA (or extension coil, or extension loop) has oneend extending from an end of the coupler coil CC, and another endextending from an end of the card antenna CA, and exhibits a cross-over.The extension antenna EA is disposed so as to have a portion adjacenttwo sides (or approximately 180°) of the coupler coil CC.

In this example, the layout of the inner winding (IW) and outer windings(OW) of the card antenna CA are slightly different than in FIG. 4A. Theinner winding IW of the card antenna CA passes over the extensionantenna EA at a different location than in FIG. 4A. In this example, thecoupler coil CC forms a closed loop (rather than the horseshoe shown inFIG. 4A) around the antenna module AM, has a cross-over, and maytherefore may be considered to be a “true” coil.

In this example, the extension coil EA is a true coil having across-over, is disposed in the residual area (148) of the card body CB,and is shown as being disposed only in the upper half (120 a) of thecard body CB, but it may extend to the lower half (120 b) of the cardbody CB and into the embossing area (146). In this example, theextension antenna (EA) may occupy a larger area and have a narrowerpitch (closer spacing of windings) than the extension antenna EA of FIG.4A.

A benefit of having the extension antenna EA in a booster antenna BA maybe to increase the inductivity of the booster antenna BA while reducingits resonance frequency. For example, without the extension antenna EA,the card antenna CA may require significantly more windings (such as inexcess of 15 windings, instead of only 7 or 8 windings), depending onthe spacing between the windings and the diameter or cross sectionalarea of the conductor of the wire used to form the booster antenna BA.It is within the scope of the invention that the card antenna CA hasonly one winding.

Additionally, the extension antenna EA may increase the inductivecoupling between the module antenna MA of the antenna module AM and thecoupler coil CC of the booster antenna BA, and this may be moreimportant than increasing the inductivity of the booster antenna BA. Ahigh level of inductive coupling between (using transformer terminology)the “primary side” (coupler coil) and the “secondary side” (moduleantenna) improves the transfer of energy and communication (signaling)integrity. Better coupling may also reduce the quality factor (Q) andincrease performance.

The booster antennas (BA) of FIGS. 4A and 4B both show card antennas CAhaving an inner winding (IW) and an outer winding (OW). Compare FIG. 2.

FIG. 4C is a diagram showing a booster antenna BA having a card antennaCA, a coupler coil CC and an extension antenna EA. These components maybe formed (embedded in the card body CB) as one continuous embeddedcoil. The coupler coil CC is in the form of an open loop (“horseshoe”).

The extension antenna EA (or extension coil, or extension loop) has oneend extending from an end of the card antenna CA, its other end is afree end. The extension antenna EA is disposed so as to have a portionadjacent one side (or approximately 90°) of the coupler coil CC.

The card antenna CA may be a single coil (not having an inner winding IWand an outer winding OW as in some of the previous examples), having onefree end.

The coupler coil CC may be a open loop, rather than a “true coil”, andmay be horseshoe-shaped, encircling most, but not all of the couplingarea (144).

The extension antenna EA may be a continuation of an end of the cardantenna CA, and may have one free end which is left unconnected. Theextension antenna EA my be disposed to interact on one side of thecoupler coil CC. The extension antenna EA may have several turns ofwire, but does not need a cross-over.

FIG. 4D is a diagram showing a booster antenna BA having a card antennaCA, a coupler coil CC and an extension antenna EA. These components maybe formed (embedded in the card body CB) as one continuous embeddedcoil. The coupler coil CC is in the form of an open loop (“horseshoe”).

The extension antenna EA (or extension coil, or extension loop) has oneend extending from an end of the card antenna CA, its other end is afree end. The extension antenna EA is disposed so as to have a portionadjacent two sides (or approximately 180°) of the coupler coil CC.

In this example, the card antenna CA is one coil (does not have innerwinding IW and outer winding OW as in some of the previous examples.) Inthis example, the coupler coil CC is not a “true coil”, it ishorseshoe-shaped and encircles most, but not all of the coupling area(144).

The extension antenna EA has one end which is an extension of thecoupler coil CC, the other end is a free end. A free end makes possiblethe arrangement of a coil without a cross-over. In this example, theextension antenna (EA) is disposed to have portions adjacent two sidesof the coupler antenna (CC).

In some of the booster antenna BA designs described herein, the cardantenna CA component of the booster antenna BA may have a total of 12windings (or turns)—for example, 6 windings each for the inner windingIW and outer winding OW, or a total of 12 for a simple card antenna CA.The extension antenna EA may have two functions, firstly to lower theresonance frequency of the booster antenna BA to the desired resonanceof 13.56 MHz from approximately 18.00 MHz, for example with only 10windings (wire diameter 80 to 112 μm and a pitch of 100 μm) in theantenna extension EA may reduce the resonance frequency by 5 MHz, andsecondly to regulate or concentrate the electromagnetic field when inclose coupling proximity to the external contactless reader (see FIG. 1)at around 20 mm. The extension antenna EA may increase the couplingfactor between the coupler coil CC and the module antenna MA of theantenna module AM.

The ability to reduce the number of windings required in the cardantenna CA may enhance the performance and manufacturability of thesmart card. More windings makes the card stiffer, and there is not a lotof room in the peripheral area (142) of the card body CB, particularlybelow the embossing area (146) to accommodate very many turns of wire.

A “coupling area” (144) may be defined as the area immediately under theantenna module AM (and its module antenna (MA)). The coupler coil CC maybe typically located in the coupling area. The extension antennas EA maybe disposed in other than the coupling area, as discussed above, butnevertheless may enhance the overall coupling between the boosterantenna BA and the module antenna MA, and/or the booster antenna BA andthe antenna of an external reader.

In FIGS. 4C and 4D, the one end of the extension antenna EA may beconnected with the coupler coil CC, rather than with the card antennaCA.

FIGS. 4C and 4D illustrate how the shape and position of the extensionantenna EA may be varied, with respect to the card antenna CA andcoupler antenna CC, in order to tune the RF characteristics of thebooster antenna BA. FIG. 4C shows a design where the extension antennaEA may be disposed along only one side of the coupler coil CC, orcoupler antenna) and two sides of the card antenna CA. FIG. 4D shows theextension antenna EA disposed adjacent two sides of the coupler antenna(CC) and two sides of the card antenna CA.

A number of benefits may be attributable to the use of an extensionantenna EA as a component of a booster antenna BA. Some variations ofthe extension antenna EA include how it is disposed with respect to thecoupler coil CC component, as well as how it is disposed with respect tothe card antenna CA component. The extension antenna EA may be a truecoil, connected at at least one of its two ends to one or both of thecoupler coil CC and card antenna CA. Its other end may also be connectedto one or both of the coupler coil CC and card antenna CA, or may remainas a free end.

FIG. 4E is a diagram showing a booster antenna BA having a card antennaCA, a coupler coil CC and an extension antenna EA. These components maybe formed (embedded in the card body CB) as one continuous embeddedcoil. The coupler coil CC is in the form of a closed loop.

The extension antenna EA (or extension coil, or extension loop) has oneend extending from an end of the coupler coil CC, its other end is afree end. The extension antenna EA is disposed so as to have a portionadjacent two sides (or approximately 180°) of the coupler coil CC.

The card antenna CA may comprise one coil (without an inner winding IWand an outer winding OW as in some of the previous examples), and mayhave a free end. In this example, the coupler coil CC is a true coil,and has a cross-over.

This design features a low number of turns at the perimeter of the cardbody CB below the embossing area (or “5^(th) line” of embossing). Theextension antenna (EA) may be disposed to have portions adjacent twosides of the coupler antenna (CC), and may have a free end.

In this example, the extension antenna EA have one end extending fromthe coupler coil CC and its other end may be a free end. The extensionantenna EA may be disposed along two sides of the coupler antenna (CC).

Booster Antenna BA components disposed primarily in the top half of theCard Body CB

Reference is made to U.S. Ser. No. 13/600,140 filed 30 Aug. 2012 (now US20130075477), particularly FIGS. 6A,B,C thereof, and also to U.S.61/697,825 filed 7 Sep. 2012, particularly FIG. 6D thereof, all of whichare incorporated by reference herein.

FIG. 4F shows that the booster antenna BA may extend around theperipheral area (142) of the card body CB, and also into the couplingarea (144) and the residual area (148), while avoiding the embossingarea (146). In this example, the coupler coil CC and extension antennaEA are essentially combined with one another, as a coil wherein theturns increase in pitch as the combined CC/EA booster antenna componentextends across the residual area.

There is no true center to the coil formed by the combined coupler coilCC and extension antenna EA components, and the antenna module AM ispositioned asymmetrically with respect to the combined CC/EA antennacomponent, and the degree of asymmetry can be varied by varying thepitch of the turns within the extension antenna (EA) in the area abovethe embossing area.

FIG. 4G is a diagram showing a booster antenna (BA) having a cardantenna CA, a coupler coil CC and an extension antenna (EA). Thesecomponents may be formed (embedded in the card body CB) as onecontinuous embedded coil.

The extension antenna EA has one end connected with an end of thecoupler coil CC, its other end is a free end. The pitch (spacing betweenturns) of the extension antenna EA may be different than the pitch ofthe coupler coil CC. Both the extension antenna EA and coupler coil CCmay have pitches different than that of the card antenna CA.

The coupler coil CC is shown as a “true” coil (closed loop), having acrossover. The extension antenna EA may be connected at one end to oneend of the coupler coil CC, the other end of the extension antenna EAmay be a free end (not connected to another booster antenna BAcomponent. The extension antenna EA may not have a cross-over. Theextension antenna EA may have a pitch (spacing between adjacent turns)which is different than that of the coupler coil CC, and the pitch canbe selected in order to vary the capacitance of the extension antenna(EA) and hence tune the resonance frequency of the booster antenna (BA).The components of the booster antenna (BA) may be formed as a continuouswire embedded coil.

FIG. 4H is a diagram showing a booster antenna (BA) having a cardantenna CA, a coupler coil CC and an extension antenna (EA). Thesecomponents may be formed (embedded in the card body CB) as onecontinuous embedded coil.

The extension antenna EA has one end connected with an end of thecoupler coil CC, its other end is a free end. The pitch (spacing betweenturns) of the extension antenna EA may be formed with varyingpitches—for example, increasing in pitch towards its inner turns (versusits outer turns), for example a narrow pitch at the outer turns and awider pitch at the inner turns of the extension antenna EA. The pitch ofindividual turns of the extension antenna EA may be adjusted to matchthe booster antenna (BA) resonance frequency.

FIG. 4I is an illustration of a booster antenna (BA) with card antennaCA, a coupler antenna (CC) and an extension antenna (EA). The antennamay be laid on the card body CB as a continuous embedded coil.

The extension antenna EA comprises two coils EA-1 and EA-2 which may beconnected in series with one another, as shown. One end of the coil EA-1is connected with an end of the coupler coil CC, the other end of thecoupler coil CC may be a free end. The other end of the coil EA-1 isconnected with a first end of the coil EA-2. The other end of the coilEA-2 is connected with an end of the card antenna CA, the other end ofthe card antenna CA may be a free end. The two coils EA-1 and EA-2 ofthe extension antenna EA may be laid with the same sense (bothclockwise), or with opposite senses (one clockwise, the other counterclockwise).

This concept can be applied to more than two extension antennas (EAs).The two or more extension antennas (EAs) may have independentlydifferent sizes, shapes, pitch and number of turns, and each one mayhave a varying (increasing or decreasing) pitch. The use of multipleextension antennas (EAs) allows for flexibility in the design of theextension antenna (EA) system in order to tune, including adjusting atleast one of the inductance and the resonance frequency, of the boosterantenna (BA). The use of multiple extension antennas (EAs) canultimately improve the coupling between the booster antenna (BA) and themodule antenna (MA).

In the various embodiments disclosed herein, the booster antenna BA maybe a continuous embedded coil(s) of wire. All of the antenna componentsmay be formed from a single continuous length of wire. Some of thecomponents, or some portions thereof may be formed from conductivetracks other than wire, such as by additive (e.g., printing) orsubtractive (e.g., etching) processes.

Some Additional Configurations of the Coupler Coil (CC)

FIG. 5A shows a booster antenna BA with a coupler coil CC. Details suchas outer winding OW and inner winding IW of the booster antenna BA areomitted, for illustrative clarity. An antenna module AM with moduleantenna MA may be mounted in the card body CB (not shown), as describedabove.

Here it can be observed that the middle of the antenna module AM, whichmay be nominally (typically) coincident with the center of the moduleantenna MA, is offset noticeably from (substantially non-coincidentwith) the middle (center) of the coupler coil CC.

The offset between the center of the module antenna MA from the centerof the coupler coil CC need not be great to avoid any implication thatthey are substantially coincident (substantially concentric). First ofall, the antenna module AM and its module antenna MA measure onlyapproximately 8 mm-10 mm on a side (square). One millimeter is asignificant offset on this scale. Furthermore, whereas U.S. Pat. No.5,955,723 (Siemens, 1999) is adamant that the coupler coil (third loop)and module antenna (first loop) must be disposed “substantiallyconcentrically”, better coupling may be achieved by having the offsetshown in FIG. 5A. And the offset may facilitate overlapping of themodule antenna MA with one or two sides of the coupler coil CC, forincreased coupling therebetween. In FIG. 5A it may be observed that themodule antenna MA overlaps the bottom and left sides of the coupler coilCC. (The module antenna MA and coupler coil CC are both somewhatrectangular, each having four sides.)

FIG. 5B is an illustration of a booster antenna (BA) with a coupler coil(CC) having a free end, and shows a booster antenna BA having an cardantenna CA (peripheral portion) which may be referred to as an “outercoil” OC and a coupler coil CC (coupler portion) which may be referredto as an inner coil IC defines a coupling area for the antenna module AM(not shown). Overall, there are only two free ends—an end “A” of theouter coil OC, and an end “B” of the inner coil IC.

The outer coil OC is shown being laid from its end “A” counterclockwiseCCW, from inner turn to outer turn, then after approximately 10 turns,heading inward to start laying the inner coil IC. The inner coil IC isshown being laid clockwise (CW), from an outer turn to an inner turn,then after approximately 20 turns ending at the point “B”.

The sense CW of the inner coil IC is shown opposite from the sense CCWof the outer coil OC. They may, however, have the same sense.

The outer coil OC is shown being laid from innermost to outermost turn.Alternatively, it may be laid from outermost turn to innermost turn.

The inner coil IC is shown being laid from outermost turn to innermostturn. Alternatively, it may be laid from innermost turn to outermostturn.

The pitches for the inner coil IC and outer coil OC may be the same, ordifferent than one another. The pitches for each of the inner coil ICand outer coil OC may be non-uniform, including progressive, such asincreasing from turn-to-turn from inner to outer turns of the respectivecoil.

FIG. 5C shows a booster antenna BA having two windings or parts,designated “Part 1” and “Part 2”. Each of these parts has two free ends,and has an outer peripheral portion and an inner coupling portion.

The outer peripheral portion of each part may be laid from its end,counterclockwise CCW, from an inner turn to an outer turn, then afterapproximately 5 turns, thereafter heading inward to start laying theinner portion. The inner portions are shown being laid alsocounterclockwise CCW, from an outer turn to an inner turn, then afterapproximately 10 turns ending at the point “B”. The number of turns ismerely illustrative, and the senses can be reversed.

The two parts—Part 1 and Part 2—may be realized interleaved (asillustrated) on the same surface of a substrate (card body CB), or onopposite sides of the substrate, or on two layers of a multi-layersubstrate. The two parts may be substantially identical with oneanother.

FIG. 5D shows that a peripheral portion of the booster antenna BA mayhave no free ends (it is continuous), and the coupler coil CC may havetwo free ends. This configuration may be laid starting at point A, at aninterior turn of the coupler coil CC, proceeding counterclockwise CCWand outward to an outer turn of the coupler coil CC, moving towards theperiphery of the card body CB and proceeding clockwise CW, laying theperipheral portion of the booster antenna BA from inside turn to outsideturn, then returning to the interior of the card body CB to completelaying the coupler coil CC from an inner turn, proceedingcounterclockwise CCW to the interior turn and ending at a point B on theinterior turn (which may be the same interior turn as point A). Points Aand B are the two free ends of the single wire (or conductive track)forming the booster antenna BA. The outer portion may compriseapproximately 7-8 turns, the inner portion may comprise approximately 10turns.

Other alternative designs are possible. For example, connecting ends ofthe module antenna MA to a portion or end of the booster antenna BA orcoupler coil CC (or similar portion of a booster antenna BA.

A “Folded” Coupler Coil

U.S. 61/841,286 filed 29 Jun. 2013 (Finn, Czornack) discloses a “folded”coupler coil. See FIGS. 5A, 5B therein.

FIG. 5E shows a booster antenna BA and its coupler coil component CC.The coupler coil CC in this example has two ends, several windings, andmay be formed by embedding a wire nearly all (such as approximatelythree-quarters of the way of the way around a coupling area (144), thereversing direction and going back to the starting position, thenreversing position and again going three-quarters of the way around thecoupling area, and so forth.

The card antenna CA of the booster antenna BA is shown having only a fewturns, for illustrative clarity, and exhibits a cross-over. The couplercoil CC is shown without a cross-over, one end of the coupler coil CCbeing connected to an inner winding of the card antenna CA, the otherend of the coupler coil CC being connected to an outer winding of thecard antenna CA.

A Compound Booster Antenna (BA)

FIGS. 5F,G,H illustrate forming two booster antennas, each having apartial coupler coil, in two different planes, such as one boosterantenna on each of two opposite sides of the card body (substrate), oron two separate layers which may then be laminated together.

FIG. 5I shows that a first booster antenna BA-1 may be formed on oneside of the card body CB with its coupler coil component CC-1 encirclingthe top half (approximately 180°) of the antenna module AM. FIG. 5Jshows that a second booster antenna BA-2 may be formed on the oppositeside of the card body CB with its coupler coil component CC-2 encirclingthe bottom half (approximately 180°) of the antenna module AM.

Each of the booster antennas BA-1, BA-2 may comprise a outer winding OWand inner winding IW, and may have two free ends “a” and “f”. The freeends (a, f) of the booster antennas BA-1, BA-2 are shown towards thebottom of the right edge of the card body CB.

FIGS. 5F and 5G show an embossing area (in dashed lines) on the bottomportion of the card body CB, which is an area “reserved” for embossing,in which the booster antennas BA-1 and BA-2 should not encroach. Theymay however pass along (just inside of) the bottom edge of the card bodyCB.

FIG. 5H shows that in combination with one another, the two boosterantennas BA-1 and BA-2 provide full enclosure (approximately 360°) ofthe antenna module AM. In FIG. 5K, the card body (CB) and antenna module(AM) are omitted, for illustrative clarity. The two booster antennasBA-1 and BA-2 may constitute what may be referred to as a “compositebooster antenna”.

It should be understood that in various ones of the configurations forbooster antennas shown herein that booster antennas other than FIG. 2type quasi-dipole (Q-D) booster antenna (BA) may be employed to achievethe desired enclosure of the antenna module AM and consequentimprovements to coupling between the module antenna and the boosterantenna.

Some Additional Arrangements of a Booster Antenna (BA)

In the following embodiments, the antenna module (AM) is disposed on theupper portion of the card body (CB) of a smart card, in a conventionalmanner, and the booster antenna (BA) is also disposed primarily(substantially, including fully) on the upper portion of the card body(CB). The lower portion (Embossing Area) of the card body CB is“reserved” for embossing, and other than a small area at the perimeteris generally not available for a booster antenna.

FIG. 6A (similar to FIG. 4F) illustrates a smart card having a card bodyCB, an antenna module AM disposed in the upper portion of the card bodyCB. A booster antenna BA is generally in the form of a rectangularspiral of wire (or other conductive material), having two free ends “a”and “f”. Only a representative few turns of the booster antenna BA areillustrated.

A portion 612 a of the booster antenna BA is closely spiraled around theantenna module AM in the manner of the coupler coils (CC) describedhereinabove with respect to FIGS. 3, 3A-3D. This “coupler portion” 612 aof the booster antenna BA may have a relatively small pitch. Althoughthe coupler portion 612 a is shown as being at one end portion of theoverall booster antenna BA, it may be created at a portion, such as amidsection of the booster antenna BA.

A remaining portion 614 a of the booster antenna BA has a pitch that mayincrease across the width of the card body. The general idea is that thebooster antenna BA may cover substantially the entire width of the cardbody. Since the width of the card body is greater than its height, evenmore so when comparing the width of the card body with the height of theupper portion only, there is more room in the width dimension for theturns of the booster antenna to spread out, and this area may beadvantageously utilized.

If the coupler portion 612 a were formed at a midsection of the overallbooster antenna BA (rather than at one end, as shown), the remainingportion 614 a of the booster antenna would have two portions (or“poles”) extending from the coupler portion 612 a, forming a kind ofdipole antenna. This would be analogous to the FIG. 3 type boosterantenna, described as a “quasi-dipole” which has an outer winding OW andan inner winding IW extending from a more-or-less central coupler coilCC.

FIG. 6B illustrates a smart card having a card body CB, an antennamodule AM disposed in the upper portion of the card body CB. A boosterantenna BA is generally in the form of a rectangular loop of wire (orother conductive material), having two free ends “a” and “f”. Only arepresentative few turns of the booster antenna BA are illustrated.

A portion 612 b of the booster antenna BA, which may be referred to as a“coupler portion”, is closely spiraled around the antenna module AM inthe manner of the coupler coils (CC) described hereinabove with respectto FIGS. 3, 3A-3D.

A remaining portion 614 b of the booster antenna BA extends across thewidth of the card body, and includes a portion which is formed with azig-zag, for improved capacitance. This remaining portion 614 mayexhibit a spiral pattern.

In the embodiments of FIGS. 6A and 6B, the booster antenna BA isillustrated disposed entirely within the upper portion of the card bodyCB, not encroaching on the lower embossing area. However, it is evidentthat the ends “a” and “f” of the booster antenna(s) could extend intothe embossing area.

FIG. 6C illustrates a smart card having a card body CB, an antennamodule AM disposed in the upper portion of the card body CB. A boosterantenna BA is generally in the form of a rectangular loop of wire (orother conductive material), having two free ends “a” and “f”. Only arepresentative few turns of the booster antenna BA are illustrated.

A portion 612 c of the booster antenna BA, which may be referred to as a“coupler portion”, is closely spiraled around the antenna module AM inthe manner of the coupler coils (CC) described hereinabove with respectto FIGS. 3, 3A-3D.

In this example, the coupler portion 612 c is shown formed at amidsection of the overall booster antenna BA (rather than at one end, asshown), and there are two remaining portions 614 c, 614 d of the boosterantenna BA extending from the coupler portion 612 c, forming a kind ofdipole antenna. This is somewhat analogous to the FIG. 2 type boosterantenna, described as a “quasi-dipole” which has an outer winding OW andan inner winding IW extending from a more-or-less central coupler coilCC.

The remaining portion 614 c extends from one end of the coupler portion612 c along a side edge (left side, as viewed) of the card body CB intothe embossing area. (This is acceptable to have a portion of the boosterantenna BA in a peripheral region only of the embossing area.)

The remaining portion 614 d extends from the other end of the couplerportion 612 c along the top edge of the card body CB to the right (asviewed) side edge thereof, thereafter extending down the right edge ofthe card body CB into the embossing area.

The booster antenna BA with remaining portions 614 c and 614 d extendingfrom the two ends of the coupler portion 612 c) forms a kind of dipoleantenna which is somewhat analogous to the FIG. 2 type booster antenna.

FIG. 6D shows a configuration for a card antenna CA having an outerwinding OW and an inner winding IW. The card antennas describedhereinabove occupy substantially the entire peripheral portion of thecard body CB, the card antenna CA is disposed within and near all four(top, right, left, bottom) edges of the card body CB. In contrasttherewith, the card antenna CA of FIG. 8 occupies only approximately thetop half of the surface of the card body CB, leaving the bottom half ofthe card body CB free for embossing, etc. In other words, the cardantenna CA of FIG. 8 may extend along substantially all of the top sideedge of the card body CB, only about halfway down the right and leftside edges of the card body, and across a central portion of the cardbody. The overall area encompassed by the card antenna CA is only abouthalf of the overall area of the card body CB.

The card antenna CA may be configured as quasi-dipole with inner andouter windings (IW/OW), the outer end “b” of OW connected via jumper “j”to inner end “e” of IW, the inner end “a” of OW and outer end “f” of IWare free ends.

The module antenna MA of antenna module AM may overlap only a portion ofthe inner winding IW. There is no distinct coupler coil CC. The “center”of any given windings of the OW and IW of the card antenna CA is outsideof the area of the antenna module AM

The pitch of the turns of the outer winding OW and/or inner winding IWmay vary (such as increase) across the width of the card body CB, asillustrated.

Some Characteristics of the Booster Antenna and its Components

The booster antenna BA and its various components may be formed ofvarious size wire ranging, for example, from approximately 50μm to 112μmin diameter. A single continuous wire may be modified, such as with aconductive coating to have different diameters for different ones of thebooster antenna components. Flat wire can also be used, and may bebeneficial for booster antenna components which may extend into theembossing area (146). Wires having different resistances, or a singlecontinuous wire having portions with different resistances may be usedfor the various components of the booster antenna.

The number of turns and the spacing of the turns of the booster antennaBA and its various components may be varied to control characteristicsof the booster antenna BA and its performance.

Distinguishing Over Some of the Prior Art

U.S. Pat. No. 5,955,723 (Siemens; 1999), incorporated by referenceherein, discloses a contactless chip card having a first conductor loopconnected to the semiconductor chip and at least one second conductorloop with approximately the dimensions of the data carrier, and a regionforming a third loop with approximately the dimensions of the firstconductor loop. Inductive coupling is described.

In the Siemens patent, there is no disclosure of an additional antennaextension (EA), nor is there any disclosure of the conductor loops(comparable to the “booster antenna” BA described herein) componentsextending into the embossing area (146) or into the residual area (148)(or embossing are) of a card body (CB), as disclosed herein.

U.S. Pat. No. 8,130,166 (Assa Abloy; 2012), incorporated by referenceherein, discloses a coupling device is formed by a continuous conductivepath having a central section in the form of a small spiral and twoextremity sections which are formed as large spirals. The pitches of thelarge spirals are chosen such that the large spirals have mainly acapacitive behavior. The pitch of the small spiral is chosen such thatthe small spiral has mainly an inductive behavior.

In the Assa Abloy patent, the large spirals appear to be in theperipheral area (142), and the small spiral appears to be in thecoupling area (144). There is no disclosure of an additional antennaextension (EA), nor is there any disclosure of the coupling device(comparable to the “booster antenna” BA described herein) components(small and large spirals) extending into the embossing area (146) orinto the residual area (148) (or embossing are) of a card body (CB), asdisclosed herein.

US 20130146671 (Infineon; 2013), discloses a booster antenna structurefor a chip card, which may include an additional electrically conductivestructure connected to the booster antenna. The additional electricallyconductive structures disclosed therein are principally capacitivestructures. FIG. 11A (for example) shows a booster antenna structurewith a finger capacitor. FIG. 12A (for example) shows a booster antennastructure with a spiral capacitor. FIG. 12B (for example) shows abooster antenna structure with a dummy turn as capacitor. FIG. 13A showsa meander shape (the additional electrically conductive structure mayhave a meander structure). The structures which form the capacitor, andthe booster antenna structure, may be arranged in the same plane. Inthis case, no additional structural layer is required in which one ofthe components is arranged separately, but both the structures formingthe capacitor and the booster antenna structure may be formed in aforming process on the same layer, i.e. in the same plane, that is tosay, for example, on one or on two sides of the carrier on which thebooster antenna structure is arranged. The capacitor may also beconfigured as line capacitor and arranged, for example, as dummy turn.The dummy turn may have two conductor tracks extending next to oneanother, the winding direction of the two conductor tracks beingopposite with respect to one another so that the dummy turn does notsupply any or a negligible contribution to the inductance of the boosterantenna structure.

The Infineon publication discloses various embodiments of a boosterantenna structure for a chip card, wherein the booster antenna structuremay include a booster antenna; and an additional electrically conductivestructure connected to the booster antenna. Attention may be directed toFIGS. 7, 8B, 9, 12A, 12B, and 13-15 therein, wherein:

FIG. 7 shows a section of a booster antenna structure according tovarious embodiments;

FIG. 9 shows a circuit diagram of a system of reading unit and acontactless chip card module arrangement according to variousembodiments;

FIG. 9 shows a circuit diagram 900 of a system having a reading unit 902(also called PCD (proximity coupling device)) and a contactless chipcard module arrangement 904 (also called PICC (proximity integratedcircuit card)) . . . . The chip card module 908 has an off-chip coil 918which is connected to the chip which is modeled by a parallel circuit ofan on-chip capacitor 920 and an on-chip resistor 922, the latterrepresenting the ohmic consumption of the chip . . . . The boosterantenna structure 906 is represented by a resonant circuit in the formof a series circuit which has a booster antenna coil 912, a boostercapacitor 914 and an additional electrically conductive structure, forexample a booster resistor 916. In the circuit of the booster antennastructure 906, the booster resistor 916 may also be connectedalternatively in parallel with the arrangement which has the boosterantenna coil 912 and the booster capacitor 914.

Claim 1 is directed to A booster antenna structure for a chip card,wherein the booster antenna structure comprises: a booster antenna; andan additional electrically conductive structure connected to the boosterantenna.

FIG. 12A shows a booster antenna structure according to variousembodiments with a spiral capacitor;

FIG. 12B shows a booster antenna structure according to variousembodiments with a dummy turn as capacitor;

A further possible form which the capacitance can have is shown in FIG.12A. To illustrate, the booster antenna structure 1200 is here alsorepresented by only one turn 1202 and connected to a spiral capacitor1204. A spiral capacitor 1204 may be understood in various embodimentsto be a capacitor which has two conductor tracks forming a conductortrack string and extending next to one another, the conductor trackstring being rolled together to form a spiral. In this arrangement, thespiral does not need to have a circular shape, it can also be oval or apolygon having rounded corners. The capacitance value of the spiralcapacitor is adjustable, for example by adapting parameters which havealready been mentioned in conjunction with the finger capacitor.

Another further possible shape which the capacitance can have is shownin FIG. 12B. The booster antenna structure 1210 has three turns 1212 inthis case. Furthermore, the end of the inner turn of the turns 1212 ofthe booster antenna structure 1210 is followed by an inductive couplingarea 1216 which is surrounded by coupling turns 1218. The, for example,three coupling turns 1218 are here formed from an extension of one endof an inner turn of the turns 1212 of the booster antenna structure1210. The end of the conductor track formed by the coupling turns 1218is followed by a dummy turn 1214 which forms the capacitor. The dummyturn 1214 has two conductor tracks extending in parallel next to oneanother, the first conductor track 1220 being coupled to the end of theconductor track which forms the coupling turns 1218 and the secondconductor track 1222 being coupled to the end of the outer turn of theturns 1212 of the booster antenna structure 1210. The first conductortrack 1220 and the second conductor track 1222 have an oppositedirection of circulation with respect to one another. The ends of thefirst conductor track 1220 and of the second conductor track 1222 areopen or are not connected to any other structure analogously to the endof the conductor track double string which forms the spiral capacitance1204 in FIG. 12A. The double string which is formed by the firstconductor track 1220 and the second conductor track 1222 as such has twoturns, wherein its course can deviate from the course shown in FIG. 12Band can be matched to unoccupied areas in the plane of the boosterantenna structure 1210 or to areas to be kept free which, for example,are reserved for embossed lettering.

It may be noted that the turns or tracks in the Infineon publication arenot shown crossing over one another. Therefore, they do not form a“true” coil which would contribute to the inductance of the boosterantenna. Compare U.S. Pat. No. 8,130,166 (Assa Abloy; 2012) which shows(FIGS. 3, 5, 6 therein) crossovers for all of their spirals (boosterantenna components). In the present invention, the antenna extension EAis in the form of a “true” coil, involves at least one crossover, andcontributes to the inductance of the booster antenna BA.

Controlling Force and Ultrasonic Power During Wire Embedding

An embedding head (or tool) for embedding the wire for the boosterantenna BA and its various components in the substrate may comprise anultrasonic transducer (or sonotrode) vibrating a capillary tube throughwhich the wire being embedded extends (or is fed) onto the surface ofthe substrate. By imparting an ultrasonic vibration of the tool whileapplying a downward force (urging the tool downward, with a force), thewire may be caused to embed itself, at least partially, into the surfaceof the card body CB substrate. Reference may be made to U.S. Pat. No.6,698,089 (2004; Finn et al) and U.S. Pat. No. 6,233,818 (2001; Finn etal), incorporated by reference herein, which disclose embedding wire ina substrate using a sonotrode. See, for example, FIGS. 1 and 3 of the'089 patent.

The booster antenna (BA) (and any of its components CA, OW, 1 W, CC, AE)may comprise several turns of wire embedded very close to one another.When embedding the several turns of a booster antenna (BA), notably theperipheral card antenna (CA) portion thereof, it may be appreciated thatthe first turn of wire may be embedded in the “native” substrate of thecard body (CB), and may interfere (resisting or blocking, in a manner ofspeaking) with the embedding of subsequent turns of the booster antenna(BA).

FIG. 7 shows the cross-section of a typical coil (booster antennacomponent) embedded on a substrate of a card body CB and shows thesequence used to scribe the 7 coil windings. A first (1^(st)) turn maybe laid or embedded in the card body CB, followed by a second (2^(nd))turn, followed by a third (3^(rd)) turn, followed by a fourth (4^(th))turn, followed by a fifth (5^(th)) turn, followed by a sixth (6^(th))turn, followed by the final seventh (7^(th)) turn. Evidently, when thesecond and subsequent turns are being embedded, the process can beresisted by the first and other previously-embedded turns.

A method is disclosed herein for controlling at least one of thedownward force which is exerted by the embedding tool and a power of theultrasonic vibration while embedding the wire in the surface of thesubstrate. Various benefits may be obtained, such as improved embeddingof the wire, more consistent embedding of the wire, and reduced pitch(closer spacing) of turns of the wire in a booster antenna BA component(for example) which may allow for more turns of wire (hence, moreinductance) in a given space (such as, but not limited to the peripheralarea 146 of the card body CB).

FIG. 7A shows a device 600 for embedding wire (such as for a boosterantenna (BA) in a substrate (card body CB) may comprise

-   -   an ultrasonic transducer    -   a sonotrode    -   a capillary with wire exiting (feeding out) from one end thereof    -   means for urging the device downward with a given force

The means for urging the device for embedding downward may comprise alinear actuator comprising a movable part with at least one coil and afixed part having magnets. The downward force imparted to the capillarymay be proportional to current flowing through the coil(s) of themovable part. For the purposes of this invention the downward motion ofthe device will be along an axis defined as the “z-axis”, setperpendicular to the plane of the card body (CB). The plane of the cardbody (CB) will be denoted the “x-y plane” with the device moving acrossthe x-y plane along an “x-axis” and a “y-axis” set perpendicular eachother.

The embedding device 600 may be based on a controlled sonotrode. Thedevice has a moving stage control system allowing downward forcecontrol.

An additional actuator (not shown), such as a pneumatic piston may beprovided to apply an upward force to the capillary when current flow tothe coil(s) is turned off, such as at the commencement and terminationof the embedding operation.

According to an aspect of the invention, a force profile may beestablished so that the force of embedding can be controlled based onposition, for example (but not limited to) applying a first force (f1)at the beginning of embedding, a second force (f2) during embedding afirst turn of a booster antenna BA, a third force (f3) during embeddingsubsequent turns of the booster antenna BA, etc. An exemplary forceprofile is presented in FIG. 7B.

During embedding of the wire, either or both of the ultrasonic powerprovided by the sonotrode and the downward force exerted by thecapillary may be controlled, and varied at different positions along thepath of embedding the wire, to facilitate embedding. For example, poweror force may be changed at turns (for example at the corner of the cardbody CB when embedding a rectangular spiral shaped card antenna CA).Better control over embedding may be achieved. Closer spacing of turnsof a given booster antenna BA coil component (IW, OW, CC, AE) may beachieved.

FIG. 7B illustrates an example of force profile for embedding a seriesof consecutive turns of a booster antenna (BA) into the substrate of acard body (CB). (Ultrasonic power may be profiled in a similar manner.)

The downward force being applied, via the capillary, during embedding,may be increased or reduced, as desired, at any given location(position) on the substrate (card body CB) during embedding of wire,such as for the booster antenna (BA), including the peripheral cardantenna (CA) portion thereof and the inner coupler coil (CC) thereof.

Typical forces may be in the range of a few hundred grams (a fewNewtons). Given a typical sonotrode diameter of approximately 4 mm thisgives typical pressures or the order of a few hundred kPa. The downwardforce being applied, via the capillary, during embedding, may be reducedto zero where the wire has to “jump over” previously-embedded wires.During embedding, control may be switched between downward force andvertical position of the capillary. The invention enables a high degreeof control over the embedding process. During embedding, at any point inthe X-Y plane of the card body (CB), several parameters can becontrolled and varied. These include: the speed of movement over theentire device in the x-y plane, the power fed to the sonotrode, theheight of the sonotrode above the sample (for example when performing ajump), the downward force exerted by the sonotrode during embedding. Ofcourse, when making a cross-over, force may be reduced to nearly zero,and the ultrasonic power may (or may not) be turned off.

Controlling Bonding of a Wire

In some cases (other than the examples of embedding the booster antennacomponents which have been described herein), it may be necessary tobond the wire to bond pads on the card body, or on the RFID chip. Forexample, when bonding a wire of an antenna coil to a module tape MT foran antenna module AM, or wire bonding the RFID chip to the module tapeMT.

Bonding of a wire to bond pads of a chip module CM or to contact pads ofinterconnects on the module tape MT may be realized using a thermode,which essentially welds the wire to the pad. The integrity of the bondsis of course important, and can be monitored with an optical inspectionsystem. During bonding, the wire is deformed, and may exhibit a diameterwhich is (for example) approximately 30% smaller than its pre-bonddiameter. A typical wire being bonded may have an initial diameter of112 μm.

According to an embodiment of the invention, the position of thethermode may be measured, with micrometer precision, to achieve adeformation of the wire in a range of values centered around a targetvalue representative of (for example) a 30% reduction in the diameter ofthe wire. The position of the thermode may be monitored to ensure thatwires which are bonded are in this range, and when they are not, thethermode may be cleaned, or the process re-calibrated to ensuresuccessful subsequent bonds.

FIG. 8 shows a wire bonder comprising a thermode, and means formeasuring position, and also shows a wire (pre-deformed) being bonded toa pad, and the resulting bonded wire which is deformed (squished). Byprecisely measuring the deformation of the wire as it is being bonded,the quality of the resulting bond can be inferred, with a high degree ofconfidence. As the thermode becomes dirty, the measured thickness maychange, and the thermode can be cleaned.

Capacitive Stubs

U.S. Ser. No. 13/931,828 filed 29 Jun. 2013 (US 20130299598, 14 Nov.2013) discloses an antenna module (AM) for a transponder (or smartcard,or secure document) including a module antenna (MA) comprising a mainantenna structure (“A”) and two additional antenna structures (“B”, “C”)connected to the main antenna structure and functioning as “capacitivestubs”.

FIGS. 9A, 9B illustrate an embodiment of an antenna module (AM) 900 fora transponder comprising

-   -   a chip module (CM) 908 having two terminals 908 a, 908 b    -   an inductive wire antenna (A) 910 formed as a flat coil of        embedded wire having a number (such as 12) of turns, and two        ends—an outer end 1 (at the end of an outer one of the turns)        and an inner end 2 (at an end of an inner one of the turns)        -   The overall length of the antenna A may be 400 mm        -   The ends 1 and 2 of the antenna A may be connected to the            terminals of the chip module.        -   The chip module may be disposed within (interior to) the            turns of the antenna A.        -   The outer turn of the antenna A may cross over inner turns            of the antenna A to be routed to the chip module CM.        -   The antenna A is an “antenna structure”.    -   capacitive antenna extensions (or stubs) B and C also formed as        flat coils of embedded wire having a number of turns, and        connected to the inductive wire antenna as described below.        -   The stubs B,C are “antenna structures”

The chip module 908 and antenna A 910 may be disposed in or on a layer922 of a multi-layer antenna substrate 900. The chip module 908 may bedisposed in a recess (pocket) 906 extending partially through the layer922 (as illustrated), or may be disposed in a recess (opening) extendingcompletely through the layer 922, with the chip module 908 beingsupported by an underlying layer 924.

The chip module is illustrated in FIG. 9B “face up”, with its terminalsfor connecting with the antenna A on its top side. Alternatively, thechip module may be orientated “face down” with its antenna-receivingterminals on its bottom side (and extend through the substrate 922, forexample), and another set of terminals (not shown) for a contactinterface on its top side.

Other variations for the AM 900 may include, but are not limited to . .. .

-   -   the antenna A may be on the bottom of the layer 922    -   the stub B 912 may be on the bottom of the layer 924    -   the stub C 914 may be on the bottom of the layer 926    -   the stubs B and C may be on the top and bottom surfaces of a        single layer which is either above or below the layer 922

The stub B 912 may be formed as a flat coil of wire having a number(such as 12) of turns and two ends—an outer end 3 of an outer turn andan inner end 4 of an inner turn—in a layer 924 overlying the layer 922.The stub B may have an overall length of approximately 400 mm, and maybe aligned with (directly over) the antenna A.

The stub C 914 may be formed as a flat coil of wire having a number(such as 12) of turns and two ends—an outer end 5 of an outer turn andan inner end 6 of an inner turn—in a layer 926 underlying the layer 922.The stub C may have an overall length of approximately 400 mm, and maybe aligned with (directly under) the antenna A. The stub C may bealigned with (directly under) the stub B. The stubs B and C may beformed by etching, printing, or other processes, instead of (other than)using embedded wire.

In the schematic view of FIG. 9A, the antenna A and stubs B, C are shownlaterally offset from each other. In FIG. 9B, the inductive wire antennaA and capacitive antenna extensions B and C are shown positioned andaligned atop one another. As best viewed in FIG. 9A, the antennastructures A, B, C may each be formed in a flat coil pattern having anumber of turns, an overall length (from end to end), and a footprint(length×width), and may be substantially identical with one another inthese regards. As best viewed in FIG. 9B, the antenna structures A, B, Cmay be disposed substantially directly over one another.

FIG. 9B illustrates that the number of turns, length, width, pitch andpattern of the stubs B, C may be substantially the same (match) as eachother and they may be aligned one atop the other in layers of theantenna module 200 so that their turns are aligned with one another,turn-for-turn. The stubs B, C may also substantially match and bealigned with the antenna A. Capacitance and the resonant circuit isformed between A+B and A+C. Antenna A is shown disposed in a layerbetween the layers for stubs B and C. Antenna A could alternatively bedisposed in a layer above or below both of the layers for stubs B and C.

Dashed lines ( - - - ) indicate that the inner end 4 of the stub B 912may be connected to the outer end 1 of the antenna A 910, such as at theterminal 908 b, and the outer end 5 of the stub C may be is connected tothe inner end 2 of the antenna A, such as at the terminal 908 b. Theouter end 3 of the stub B and the inner end 6 of the stub C may be leftunconnected (remain open).

Alternatively, the vertical arrows (↓,↑) indicate that the outer end 3of the stub B may be connected to the outer end 1 of the antenna A (suchas at terminal 208 b), and the inner end of stub C may be connected withthe inner end of the antenna A.

Note that in either case, “opposite” (inner versus outer) ends of thestubs B, C are connected to the two ends 1, 2 of the antenna A—in otherwords, the inner end 4 of B and the outer end 5 of C. As used herein,“connected in an opposite sense” means that the inner end of one of thetwo stubs (B or C) is connected with one end of the antenna (A), and theouter end of the other of the two stubs (C or B) is connected with theother end of the antenna (A). It is generally not desirable that the“same” (such as both inner) ends of the stubs are connected with theends of the antenna A. The connections (interconnects) discussed hereincan be made in any conventional manner, such as by vias through layers,traces on layers, bonding, soldering, crimping, welding, etc.

Locating the stubs B and C over each other in close proximity with theantenna A between them forms additional resonant circuits between the Aand the stubs B, C realized by the stray capacitance between the antennastructures A, B, C. The interaction between the coupled stubs B and Cexposed to the same electromagnetic field from the antenna A mayadvantageously reduce the self-resonance (or self-resonant) frequency ofthe antenna A. Stub B is close to antenna A and stub C is close toantenna A, ergo stub B is close to stub C.

In electronics, capacitors and inductors have parasitic inductance andcapacitance, respectively. For a capacitor, the inductance is primarilydue to the physical dimensions including the leads. Since a capacitorand inductor in series creates an oscillating circuit, all capacitorsand inductors will oscillate when stimulated with a step impulse. Thefrequency of this oscillation is the self-resonant frequency (SRF).

The dimensions of the antenna module 900 may be approximately 15 mm×15mm Due to the relatively small available area, an inductive wire loop ofthe size of the antenna module may have a self-resonance frequency ofapproximately 75 MHz. The over-layered close coupled antenna structures(stubs B and C) may function as a wire formed capacitor—with open wireends (3 and 6)—that may reduce the resonance frequency of the formedtransponder to a more desirable value of approximately 13-17 MHz,thereby increasing the voltage and transferred power to the chip module.

Two Module Antenna Segments (MA1, MA2)

U.S. Ser. No. 14/078,527 filed 13 Nov. 2013 discloses variousconfigurations for components (CA, CC, EA) of booster antenna (BA). Forexample, A module antenna (MA) may have two windings connected with oneanother in a quasi-dipole configuration.

FIG. 9C illustrates the underside of a module tape MT for an antennamodule (AM). An antenna structure (AS) for a module antenna (MA) isshown, comprising two module antenna segments MA1 and MA2. These twomodule antenna segments MA1, MA2 may be arranged concentric with oneanother, as inner and outer antenna structures. Both module antennasegments MA1, MA2 may be wound coils, or patterned tracks, or one may bea wound coil and the other a pattern of tracks. The two module antennasegments MA1, MA2 may be interconnected with one another in any suitablemanner to achieve an effective result.

FIG. 9D illustrates an exemplary antenna structure AS which may be usedin an antenna module AM, having two segments (compare MA1, MA2) whichare interconnected with one another, the antenna structure comprising

-   -   an outer segment OS having an outer end 7 and an inner end 8    -   an inner segment IS having an outer end 9 and an inner end 10    -   the outer end 7 of the outer segment OS is connected with the        inner end 10 of the inner segment IS    -   the inner end 8 of the outer segment OS and the outer end 9 of        the inner segment IS are left unconnected    -   this forms what may be referred to as a “quasi dipole” antenna        structure AS.        -   Such an arrangement is shown in U.S. Ser. No. 13/205,600            filed Aug. 8, 2011 (published as 20120038445, Feb. 16, 2012,            issued as U.S. Pat. No. 8,474,726 Jul. 2, 2013) for use as a            booster antenna BA in the card body CB of a smartcard SC.            See FIG. 2C therein.        -   Such an arrangement is shown in U.S. Ser. No. 13/310,718            filed Dec. 3, 2011 (published as 20120074233, Mar. 29, 2012,            issued as U.S. Pat. No. 8,366,009 Feb. 5, 2013) for use as a            booster antenna BA in the card body CB of a smartcard SC.            See FIGS. 3 and 4A therein.            Coupler Coil (CC) with Inner and Outer Windings

As mentioned in conjunction with the booster antenna (BA) shown (forexample) in FIG. 2, a single antenna component (such as the peripheralcard antenna CA) may comprise two windings, such as an inner winding andan outer winding. Module antennas having two windings rather than onehave also been discussed, for example with respect to FIGS. 9C,D.

FIGS. 10A,B,C are diagrams of some coupler coil (CC) configurations fora booster antenna (BA). The coupler coil CC may be configured in variousways to increase a coupling factor between the coupler coil CC componentof the booster antenna BA and the module antenna MA of the antennamodule AM.

FIG. 10A shows a configuration of a conventional (typical) coupler coilCC in the form of a flat coil having number (such as ten) of turns, andtwo ends “c” and “d”. The booster antenna BA extending around theperiphery of the card body is illustrated with only one turn, forillustrative clarity. The coupler coil CC may have, for example,approximately 10 turns of wire, in a flat spiral pattern.

FIG. 10B shows a coupler coil CC having inner and outer windings.Starting at one end “d” of the coupler coil CC, an inner winding iw (orinner portion IP, shown in dashed lines) has approximately 5 turns ofwire and is wound (laid) in a counter clockwise direction fromoutside-to-inside, then jumps over itself (over previously laid turns)at a “cross-over”, and an outer winding ow (or outer portion OP, shownin solid lines) has approximately 5 turns of wire and is wound (laid) ina counter clockwise direction from inside-to-outside, then terminates atthe other end “c”. It should be understood that the coupler coil CCcould be wound from “c” to “d”, rather than from “d” to “c”, and othervariations may be implemented. The inner and outer windings iw and owmay have substantially the same number of turns, five each. Fewer turnsare shown in the figure, for illustrative clarity.

FIG. 10C shows a magnetically conductive patch (e.g. ferrite) MP whichmay improve the coupling. The patch MP could e.g. be placed onto thecoupling coil CC (between the module antenna MA and the coupling coilCC). Instead of using the whole area (module and coupling coil) it couldalso be possible to create only a ring of conductive material MP aroundthe coupler coil which is outside of the module recess area covering thewires of the coupling coil only. The card antenna CA component of thebooster antenna BA, which extends around the periphery of the card bodyis shown as having only one turn, for illustrative simplicity. It shouldbe understood that the card antenna CA component may have several turns,and may include an inner winding IW and an outer winding OW.

Some Configurations of Booster Antenna (BA) Components

FIGS. 11A-11F show various exemplary configurations of a booster antennaBA. The booster antenna BA may comprise various antenna components, suchas (but not limited to):

-   -   a card antenna CA component extending around a periphery of the        card body (CB, not shown, see FIG. 1) for coupling with an        external contactless reader (see FIG. 1),        -   the card body CA component may comprise an outer winding OW            and an inner winding IW (see FIG. 1B)    -   a coupling coil CC component disposed at an interior position        (area) of the card body (CB), corresponding with a position for        the antenna module (AM, not shown) for coupling with the module        antenna (MA, not shown) of the antenna module (AM), and    -   an extension antenna (or extension coil) EA component.

The components CA, CC, EA of the booster antenna BA may beinterconnected, as shown. The components of the booster antenna maycomprise wire which is laid in a continuous path, from a starting point“a” to a finishing point “f” (or vice-versa). In some of the examples,the “sense” or laying direction (either clockwise CW, or counterclockwise CCW) of the various components may be the same, or differentthan (e.g., opposite from) the sense of other components. Some of thecomponents may be “true coils” which may form a complete loop having acrossover “x” and contributing to the inductive coupling of the boosterantenna BA. The overall booster antenna BA may have two or morecrossovers “x”. The various components may each be shown with only a fewturns, for illustrative simplicity, and are generally laid in a flatrectangular spiral pattern having a number (generally two or more)“turns”. One of the turns, or a portion thereof, may be an “innermost”turn of the booster antenna component. Another of the turns, or aportion thereof, may be an “outermost” turn of the booster antennacomponent.

Some characteristics and advantages of the various configurations shownin FIGS. 11A-11F may include, but are not limited to . . . .

-   -   altering the Q-factor of the booster antenna/module antenna        system by altering the winding direction of one or more        components (elements) making up the booster antenna BA    -   winding one or more turns of the coupler coil CC in the opposite        direction to the majority of the turns, with substantially no        increase in DC resistance, but counter-winding may broaden the        resonance curve and reduce Q-factor, and there may be no power        loss as would be the case if a resistor introduced    -   winding one or more turns of the booster antenna BA in the        opposite direction to the majority of the turns    -   winding one or more turns of the extension antenna EA in the        opposite direction to the other extension antenna EA turns, or        winding the entire extension antenna EA in the opposite        direction to the inner and outer windings (IA, OW) of the        booster antenna BA.

FIG. 11A shows a configuration for the booster antenna BA wherein fromthe starting point “a”, the wire commences being laid in a clockwise CWdirection forming outer windings (OW) of the card antenna CA (from aninnermost turn to an outermost turn), then crosses over “x” itself andheads towards the interior of the card body (CB) whereat the couplercoil CC may be formed with turns of wire laid in the counter clockwiseCCW direction (from an outermost turn to an innermost turn), thencrosses over “x” itself and heads towards the periphery of the card body(CB) for laying the extension antenna EA in a clockwise CW direction(from an outermost turn to an innermost turn), then the wire crossesover then crosses over “x” itself and heads towards the periphery of thecard body (CB) for laying the inner windings (IW) of the card antenna CAwhich may be laid in a clockwise CW direction (from an innermost turn toan outermost turn), until the finishing point “f”. the entire sequencemay be performed in reverse, starting at the point “f” and finishing atthe point “a”.

FIG. 11B shows a configuration for the booster antenna BA wherein fromthe starting point “a”, the wire commences being laid in a clockwise CWdirection forming outer windings (OW) of the card antenna CA (from aninnermost turn to an outermost turn), then crosses over “x” itself andheads towards the interior of the card body (CB) whereat the couplercoil CC may be formed with turns of wire laid in the counter clockwiseCCW direction (from an outmost turn to an innermost turn), then crossesover “x” itself and heads towards the periphery of the card body (CB)for laying the extension antenna EA in a counter clockwise CCW direction(from an outermost turn to an innermost turn), then the wire crossesover then crosses over “x” itself and heads towards the periphery of thecard body (CB) for laying the inner windings (IW, compare FIG. 1B) ofthe card antenna CA which may be laid in a clockwise CW direction (froman innermost turn to an outermost turn), until the finishing point “f”.the entire sequence may be performed in reverse, starting at the point“f” and finishing at the point “a”.

FIG. 11C shows a configuration for the booster antenna BA wherein fromthe starting point “a”, the wire commences being laid in a clockwise CWdirection forming outer windings (OW) of the card antenna CA (from aninnermost turn to an outermost turn), then crosses over “x” itself andheads towards the interior of the card body (CB) whereat the couplercoil CC may be formed with turns of wire laid in the counter clockwiseCCW direction (from an outermost turn to an innermost turn), then thewire crosses over “x” itself and heads towards the periphery of the cardbody (CB) for laying the extension antenna EA in a clockwise CWdirection (from an outermost turn to an innermost turn), then the wirecrosses over “x” itself and heads towards the periphery of the card body(CB) for laying the inner windings (IW) of the card antenna CA which maybe laid in a clockwise CW direction (from an innermost turn to anoutermost turn), until the finishing point “f”. the entire sequence maybe performed in reverse, starting at the point “f” and finishing at thepoint “a”.

FIG. 11D shows a configuration for the booster antenna BA wherein fromthe starting point “a”, the wire commences being laid in a clockwise CWdirection forming outer windings (OW) of the card antenna CA (from aninnermost turn to an outermost turn), then crosses over “x” itself andheads towards the interior of the card body (CB) whereat the couplercoil CC may be formed with turns of wire laid in the counter clockwiseCCW direction (from an outermost turn to an innermost turn), then thewire crosses over “x” itself and heads towards the periphery of the cardbody (CB) for laying the extension antenna EA in a counter clockwise CCWdirection (from an outermost turn to an innermost turn), then the wirecrosses over “x” itself and heads towards the periphery of the card body(CB) for laying the inner windings (IW) of the card antenna CA which maybe laid in a clockwise CW direction (from an innermost turn to anoutermost turn), until the finishing point “f”. the entire sequence maybe performed in reverse, starting at the point “f” and finishing at thepoint “a”.

FIG. 11E shows a configuration for the booster antenna BA wherein fromthe starting point “a”, the wire commences being laid in a clockwise CWdirection forming outer windings (OW) of the card antenna CA (from aninnermost turn to an outermost turn), then crosses over “x” (x1) itselfand heads towards the interior of the card body (CB) whereat an innerportion IP of the coupler coil CC may be formed with turns of wire laidin the counter clockwise CCW direction (from an outermost turn to aninnermost turn), then the wire crosses over “x” (x2) itself and headstowards the periphery of the card body (CB) for laying the extensionantenna EA in a clockwise CW direction (from an outermost turn to aninnermost turn), then the wire crosses over “x” (x3) itself for layingan outer portion OP of the coupler coil CC with turns of wire laid inthe clockwise CW direction (from an outermost turn to an innermostturn), then the wire crosses over “x” (x4, x5) itself and heads towardsthe periphery of the card body (CB) for laying the inner windings (IW,compare FIG. 1B) of the card antenna CA which may be laid in a clockwiseCW direction (from an innermost turn to an outermost turn), until thefinishing point “f”. the entire sequence may be performed in reverse,starting at the point “f” and finishing at the point “a”.

FIG. 11F shows a configuration for the booster antenna BA wherein fromthe starting point “a”, the wire commences being laid in a clockwise CWdirection forming outer windings (OW) of the card antenna CA (from aninnermost turn to an outermost turn), then crosses over “x” itself andheads towards the interior of the card body (CB) whereat an innerportion IP (“iw”) of the coupler coil CC may be formed with turns ofwire laid in the counter clockwise CCW direction (from an outermost turnto an innermost turn), then the wire crosses over “x” itself for layingthe extension antenna EA in a counter clockwise CW direction (from anoutermost turn to an innermost turn), then the wire crosses over “x”itself for laying an outer portion OP (“ow”) of the coupler coil CC withturns of wire laid in the counter clockwise CCW direction (from anoutermost turn to an innermost turn), then the wire crosses over “x”itself and heads towards the periphery of the card body (CB) for layingthe inner windings (1 W) of the card antenna CA which may be laid in aclockwise CW direction (from an innermost turn to an outermost turn),until the finishing point “f”. the entire sequence may be performed inreverse, starting at the point “f” and finishing at the point “a”.

The following table presents the “laying” senses of the variouscomponents CA (OW, 1 W), CC, EA of the booster antenna BA. (The OW and 1W may have the same sense as one another.)

OW of CA CC EA IW of CA FIG. 11A CW CCW CW CW FIG. 11B CW CCW CCW CWFIG. 11C CW CCW CW CW FIG. 11D CW CCW CCW CW FIG. 11E CW (IP) CCW CW CW(OP) CW FIG. 11F CW (IP) CCW CCW CW (OP) CCW

Although not specifically directed to the antenna module AM, theconfigurations of and improvements to booster antennas disclosed hereinmay provide for improved coupling of the booster antenna BA with theantenna module AM, and consequent improvements in “read distance” and“activation distance”.

According to some embodiments (examples) of the invention, a boosterantenna (BA) may comprise a card antenna (CA) component disposed arounda periphery of a card body (CB) and comprising an inner winding (IW) andan outer winding (OW); a coupler coil (CC) component disposed at alocation for an antenna module (AM) on the card body (CB); and anextension antenna (EA) component; and may be characterized in that: atleast one of the components is laid having a sense which is opposite oneor more of the other components. At least some of the components mayhave innermost and outermost turns; at least one of the components islaid from an innermost turn to an outermost turn; and at least anotherof the components is laid from an outermost turn to an innermost turn.

Some Additional Embodiments of the Booster Antenna (BA)

FIG. 12 shows diagrammatically, and FIG. 12A shows more “realistically”,an exemplary embodiment of a booster antenna BA comprising a coilantenna CA component having an inner winding IW and an outer winding OW,a coupler coil component CC having an inner portion IP (or inner winding“iw”) and an outer portion OP (or outer winding “ow”), and an extensionantenna EA component. (The extension antenna EA in this embodiment isshown having a single multi-turn winding, but it could be formed with aninner and outer winding.)

The booster antenna BA may comprise insulated wire, embedded in the cardbody CB. Each component may have a number of turns, non-limitingexamples of which are given. The booster antenna BA may be laid(embedded), as follows. The number of turns, sense (clockwise, counterclockwise), and order of laying the turns and/or windings of the variousbooster antenna BA components—such as the inner winding IW and outerwinding OW of the card antenna CA component, the inner portion IP andouter portion OP of the coupler coil CC component, and (optionally) theinner and outer windings of the extension antenna EA component)—areexemplary, and may be changed, reversed, or done in a different order,and some of these elements or portions thereof may be omitted. A boosterantenna BA formed by an additive or subtractive process, resulting intraces of conductors, may exhibit a similar arrangement to the embeddedwire-based booster antenna BA described herein.

In a first step (1), at a point “a” which may be a first end of theoverall booster antenna BA, start laying (routing, embedding) the outerwinding OW of the card antenna CA component in a clockwise CW direction,for 3 or 4 turns around (just inside of) the perimeter of the card bodyCB, from an innermost turn to an outermost turn thereof. (Thediagrammatic view of FIG. 12 may show fewer number of turns, for thevarious booster antenna components, for illustrative clarity.)

In a next step (2), stop embedding, jump over the already laid turns ofthe outer winding OW, to the interior (coupling area, 144) of the cardbody CB, and lay the inner portion IP (or inner winding “iw”) of thecoupler coil CC component in a counter clockwise CCW direction, such asfor 8-10 turns, from an outermost turn to an innermost turn thereof.

In a next step (3), the wire may be lifted (jump) over the already laidinner portion IP of the coupler coil CC component to start forming formthe extension antenna EA component by laying the wire in a counterclockwise CCW direction, from an outermost winding to an innermostwinding thereof. The extension antenna EA component may have 4 turns,and may be routed around a central position of the card body CB,substantially as illustrated, and maintained at a given distance “s”from the card antenna CA component, so as to be substantiallysymmetrical (from left-to-right, as viewed).

In a next step (4), having completed laying the extension antenna EAcomponent, the embedding process continues around the already laid innerportion IP of the coupler coil CC component, forming an outer portion OP(or outer winding “ow”) of the coupler coil CC component, with a counterclockwise CCW sense (laying direction), and having 5 turns, around theexterior of the inner portion IP of the coupler coil CC component, froman outermost winding to an innermost winding thereof. In this example,the inner portion IP and outer portion OP of the coupler coil CCcomponent have the same sense (CCW). Alternatively, the inner portion IPand outer portion OP of the coupler coil CC component may be laid withopposite sense (one CW, the other CCW). The order of laying the innerportion IP and outer portion OP of the coupler coil CC component mayalso be switched (first lay the outer portion OP, then the extensionantenna EA, then the inner portion IP). Or, lay both the inner portionIP and outer portion OP of the coupler coil CC component, without“interrupting” by laying the extension antenna EA component.

In a next step (5), after completion of the outer portion OP of thecoupler coil CC component, the antenna wire may be routed to theperimeter of the card body CB to lay the inner winding IW of the cardantenna CA component in a clockwise CW direction, having 3 or 4 turns,from an innermost winding to an outermost winding thereof. Embedding maystop, as a point “f”. Compare FIG. 2, the points “a” and ‘f’ representfree (not connected) ends of the booster antenna BA, which otherwise isa continuous winding of the various components (CA, CC, EA). In thisexample, the inner winding IW and outer winding OW of the card antennaCA component have the same sense (CW). Alternatively, the inner windingIW and outer winding OW of the card antenna CA component may be laidwith opposite sense (one CW, the other CCW). The inner winding IW andouter winding OW of the card antenna CA component may also be switched(first lay the outer portion OP, then the extension antenna EA, then theinner portion IP).

FIGS. 13A-13E illustrate an example of laying the booster antenna (BA),step-by-step, or component (and portion thereof)—by—component. Forexample:

-   -   (FIG. 13A) in a first step, the outer winding OW of the card        antenna CA component may be laid, starting at a point “a”, which        is a free end of the booster antenna BA, and proceeding a number        of turns around (but spaced inside of) the outer perimeter of at        least a portion of the card body CB (card body omitted, for        illustrative clarity), in a clockwise CW direction, from an        inner turn to an outer turn thereof, to a point “g” which is an        interim point (rather than an end point);    -   (FIG. 13B) in a next step, crossing over the already laid turns        of the outer winding OW of the card antenna CA component, then        forming the inner winding iw of the coupler coil CC component by        laying the wire in a counter-clockwise CCW direction from an        outer turn to an inner turn thereof, to a point “h” which is an        interim point (rather than an end point);    -   (FIG. 13C) in a next step, crossing over the already laid turns        of the inner winding iw of the coupler coil CC component, then        forming at least a portion of the extension antenna EA component        by laying the wire in a counter-clockwise CCW direction from an        outer turn to an inner turn thereof, to a point “i” which is an        interim point (rather than an end point); (In this step, the        turns of the extension antenna EA component may cross over the        wire coming from the coupler coil CC component and the wire        coming from the outer winding OW of the card antenna CA        component.)    -   (FIG. 13D) in a next step, crossing over the wire leading to the        inner winding iw of the coupler coil CC component, then forming        the outer winding ow of the coupler coil CC component around the        inner winding iw of the coupler coil CC component by laying the        wire in a counter-clockwise CCW direction from an outer turn to        an inner turn thereof, to a point “j” which is an interim point        (rather than an end point);    -   (FIG. 13E) in a next step, crossing over the already laid        extension antenna EA component, then forming the inner winding        IW of the card antenna CA component by laying the wire in a        clockwise CW direction from an inner turn to an outer turn        thereof, to a point “f” which is a free end of the booster        antenna BA.

A booster antenna (BA) may comprise a coil antenna (CA) component havingan inner winding (IW) and an outer winding (OW), a coupler coilcomponent (CC) having an inner winding (iw) and an outer winding (ow),and an extension antenna (EA) component, wherein:

-   -   the card antenna (CA) has two ends (a, f); and    -   each component (CA, CC, EA) of the booster antenna BA and        winding thereof (IW, OW, iw, ow) has a number of turns and a        laying sense (clockwise, counter clockwise).

A booster antenna (BA) may comprise:

-   -   a card antenna (CA) component disposed around a periphery of a        card body (CB);    -   a coupler coil (CC) component disposed at an interior area of        the card body;    -   wherein the coupler coil has two ends (c, d) an inner winding        (iw) and an outer winding (ow); and    -   wherein the inner and outer windings cross over one another.

A booster antenna (BA) may incorporate one or more of the followingfeatures or characteristics, and may be formed by one or more of thefollowing steps (which may be performed in the sequence set forthherein, or in another sequence):

-   -   starting from one end (a), the outer winding (OW) of the card        antenna (CA) component may be laid in a clockwise (CW)        direction, for approximately 3 or 4 turns around (just inside        of) the perimeter of the card body (CB), from an innermost turn        to an outermost turn thereof;    -   the inner winding (iw) of the coupler coil (CC) may be laid in a        counter clockwise (CCW) direction, such as for approximately        8-10 turns, from an outermost turn to an innermost turn thereof;    -   the extension antenna (EA) component may be laid in a counter        clockwise (CCW) direction, for approximately 4 turns, from an        outermost winding to an innermost winding thereof;    -   the extension antenna (EA) may be routed around a central        position of the card body CB; the extension antenna EA is        maintained at a given distance “s” from the card antenna CA        component, so as to be substantially symmetrical;    -   the outer winding (ow) of the coupler coil (CC) component may be        laid in a counter clockwise (CCW) direction for approximately 5        turns around the inner winding (iw) of the coupler coil (CC)        component, from an outermost winding to an innermost winding        thereof;    -   the inner winding (1 W) of the card antenna (CA) component may        be laid in a clockwise CW direction, having approximately 3 or 4        turns, from an innermost winding to an outermost winding thereof    -   depending on the shape of the module antenna (MA) of the antenna        module (AM), the coupler coil (CC) component may be formed by        embedding 8 to 10 turns of wire from its outermost to its        innermost turn;    -   any of the components (or portions thereof) may be laid with a        reverse sense (such as clockwise rather than counter clockwise);    -   the components (or portions thereof) may be laid in a different        order;    -   the components (or portions thereof) may be formed by a pattern        of conductive tracks, rather than embedded wire;    -   the coupler coil (CC) component may have a rectangular, oval,        round or elongated shape;    -   iron or ferromagnetic particles or flakes may be selectively        deposited in areas between the antenna components;    -   the booster antenna (BA) may have a resonance frequency at or        below 13.56 MHz;    -   holographic metal foils may be incorporated into the inlay (card        body CB);    -   the holographic metal foils may not significantly attenuate the        electromagnetic field;    -   the holographic metal foils may generate capacitance to improve        communication performance of the smart card with an external        reader;    -   the holographic metal foils may mask the presence of the booster        antenna (BA);    -   one or more turns on the coupler coil (CC) component may be        routed in an area directly beneath an antenna module (AM).

Another Embodiment of the Booster Antenna BA

FIG. 13F illustrates another embodiment of a booster antenna BA. Somecomparisons may be made with the embodiments shown in FIGS. 4A-4E, 6D,12, 12A, and 13A-13E, and this embodiment may incorporate variousfeatures and variations shown and described therein, or elsewhere,although each and every feature and variation may not be shown in thisfigure.

The booster antenna BA may comprise:

-   -   a card antenna CA portion comprising an outer winding OW and an        inner winding IW, each winding having a number of turns, but may        comprise only a single winding. The outer and inner windings may        have the same or a different sense (CW, CCW) than one another.        The turns of the outer and inner windings may have the same or a        different pitch as one another, and may be constant or varying.    -   a coupler coil CC component comprising a single multi-turn        winding having a cross-over, but which may alternatively be        formed with an inner winding or portion (iw, IP) and an outer        winding or portion (ow, or OP). The coupler coil CC component is        shown formed as a “true coil” (compare FIGS. 4B,E,G), having a        cross-over, but may alternatively be formed as an “open loop”        (compare FIGS. 4A,C,D).    -   an extension antenna EA component comprising a single multi-turn        winding having a cross-over, but which may alternatively be        formed with inner and outer windings (in a manner similar to        that of the card antenna CA and coupler coil CC portions of the        booster antenna BA).

As illustrated, the booster antenna BA may be formed by (someillustrative steps “1” to “5”):

-   1. starting at the free end “a” of the card antenna CA component,    laying the wire for the outer winding OW, in a clockwise CW    direction, from an innermost turn to an outermost turn thereof,    around (just within) the periphery of the card body CB (not shown),-   2. then, crossing over the already laid turns of the outer winding    OW of the card antenna CA component, heading towards the interior of    the card body CB and commencing laying the wire for the coupler coil    CC component, in a counter-clockwise CCW direction, from an    outermost turn to an innermost turn thereof,-   3. then, crossing over the already laid turns of the coupler coil CC    component, commencing laying the wire for the extension antenna EA    component, in a counter-clockwise CCW direction, from an outermost    turn to an innermost turn thereof,-   4. then, crossing over the already-laid turns of the extension    antenna EA component, heading back towards the periphery of the card    body CB and commencing winding the inner winding IW of the card    antenna CA component in a clockwise CW direction, from an innermost    turn to an outermost turn thereof, within the already laid outer    winding OW,-   5. finishing laying of the wire for the booster antenna BA at the    free end “f”, which may be (but need not be) close to the other free    end “a”.

The coupler coil CC of any of the booster antenna BA componentsdisclosed herein may have a rectangular, oval, round or elongated shape(depending on the shape of the module antenna of the antenna module) isformed by embedding 8 to 10 turns of wire from the outer to the innerposition.

The extension antenna EA may have inner and outer windings. The couplercoil (CC) component may have inner and outer windings. The card antenna(CA) component may have inner and outer windings. Any of the componentsmentioned herein (CA, CC, EA) may have at least one winding in additionto its inner and outer windings.

The routing directions as indicated above can be in the reverse order.The various components (CA, CC, EA) of the booster antenna (BA),including portions thereof, may be laid from an innermost turn thereofto an outermost turn thereof, or from an outermost turn thereof to aninnermost turn thereof.

The number of turns for a given component (CA, CC, EA) of the boosterantenna (BA), including portions thereof, may change with the size ofthe booster antenna (BA). The extension antenna (EA) component may haveapproximately four turns.

The order of laying the windings of any of the booster antenna BAcomponents disclosed herein may be performed in an order other than thatwhich is described, for example, starting at the free end “f” andfinishing at the free end “a”.

The order of laying the wire from an innermost to an outermost turn (orvice-versa) may be performed in the reverse order, such as fromoutermost to innermost turn (or vice-versa).

The electrical resistance and/or material of the wire (or otherelectrical conductor) forming the windings of any of the booster antennaBA components disclosed herein may be uniform, or may varied along thelength of the card antenna CA portion.

The booster antenna BA design of this embodiment, in a dual interfacecard, may exhibit the property that the card can be interrogated byscrolling across a point-of-sale terminal without loss or impairment ofthe data.

The sense (counter clockwise) of the extension antenna EA being oppositeto the sense (clockwise) of the card antenna CA may beneficially reducethe “Q” (quality) of the booster antenna BA, may increasing thebandwidth of the booster antenna BA, and may stabilize the resonancefrequency of the booster antenna. It may be noted that the sense (CCW)of the coupler coil (CC) component may be the same as the sense (CCW) ofthe extension antenna (EA) component.

Most important is (1) because (2) and (3) are a result of this. Systemswith high quality tend to be instable and the deviation of the resonancefrequency of a transponder site is high. A stable resonance frequency isbeneficial in the production since the results can be reproduced.

A reduced quality (1) causes a broader bandwidth (2) which is anenhancement of data communication because high speed transition signalsneed a broad bandwidth in order to avoid distortion of the signal.

Some Additional Features

Iron or ferromagnetic particles or flakes could be selectively depositedin the areas between the antenna.

The booster antenna BA may be tuned, after lamination, to be below theresonance frequency of 13.56 MHz, rather than above.

Holographic metal foils may be glued or laminated to both sides of thebooster antenna BA inlay (card body DB). The holographic metal foils maynot significantly attenuate the electromagnetic field, in other wordsthe holographic metal foils may be largely transparent to the RF field.The holographic metal foils can be used to mask (visually hide) thepresence of the booster antenna BA. In addition, the holographic metalfoils when placed either side (above, below) of the booster antenna BAcan generate capacitance which may help improve the communicationperformance of the smart card with the reader (FIG. 1).

One or more turns on the coupler coil CC can be routed in the areadirectly beneath the antenna module AM. Placing some turns of thecoupler coil CC directly under the antenna module AM, and consequentlyclose to the module antenna MA, may increase the coupling between thebooster antenna BA and the antenna module AM, resulting in improvedpower delivery to the chip IC (CM), thereby improving smart cardperformance.

Compensating Loops

FIG. 14A shows a conductive “compensating (or compensation) loop” CLthat may be disposed in a layer of a card body CB, such as behind thebooster antenna BA (not shown). The compensating loop “CL” may extendaround at least a portion of the periphery of the card body CB. Thecompensating loop CL may be an open loop having two free ends, and a gap(“gap”) therebetween, and is discontinuous. The compensation loop CL maybe made of copper cladding, can be printed on a support layer, etc. FIG.14B shows that the compensating loop CL may be “closed”, having no gapand no free ends, or a continuous ring of material.

The compensating loop CL may comprise ferrite material, and may bereferred to as a “compensation frame”. Disposing the compensating loopCL on the reverse side of the booster antenna BA (away from the antennamodule AM) may help with the stabilization of the resonance frequency.The compensating loop CL may be used in addition to the booster antennaBA. The booster antenna BA may be embedded into one side of an inlaysubstrate (or card body) while the compensation frame may be inkjetprinted or adhesively attached to the opposite (from the boosterantenna) side of the inlay substrate. The compensating loop CL can bemounted using a subtractive (etching away of material) or additive(depositing material) process.

Metal Foil Layer(s)

Metal foils, metallic coatings, segments of metal foil or metalparticles may be deposited on or embedded in the inlay (or card body CB)to alter the electrical characteristics of the RFID device or smartcard.A metal foil layer in the card body construction may helps to meet theISO and EMV communication standards for RFID devices or smart cards interms of read write distance, baud rate, Q-factor bandwidth, etc. Themetal foil can be any pure metal such as aluminum or copper or an alloy.The metal foils, metallic coatings, segments of metal foil or metalparticles should have a thickness less than the skin depth of the metalor material being used in order to prevent the formation of eddycurrents in the metal or metallic structure that will attenuate the RFelectromagnetic field. The use of thicknesses substantially less thanthe skin depth of the metal or material being used will increase theelectrical resistance of the structure to alternating current flows(impedance) thereby preventing unwanted or excessive attenuation of theRF electromagnetic field. Other electrical conductors such as metalnanoparticles, metal nanowires or carbon-based conductors like graphiteor exfoliated graphite can be used to construct electrically conductivenetworks that are hereby included under the definition of a metal foilor metallic structure.

The booster antenna (BA) is normally constructed from a track of wireembedded in an inlay substrate (or card body CB) comprising one or morelayers of a material such as Polyvinyl Chloride (PVC), Polycarbonate(PC), Polyethylene (PE), Poly(ethylene terephthalate) (PET),Polyetherurethane, PET-G (Polyethylene Terephtalate Glycol-modified),Polyester Copolymer film, Teslin™, paper, synthetic paper and the like.Alternatively, the booster antenna (BA) can be formed on the inlaysubstrate by chemically or laser etching a metal coating previouslydeposited on the substrate. A particular design of booster antenna (BA)with coupler coil (CC), having a certain geometry and number of coilwindings, will exhibit specific electrical characteristics in terms ofresonance frequency and impedance.

The metallic/metallized foil in the card stackup may exhibit “capacitivecoupling” with the booster antenna (BA) to broaden the bandwidth of theGaussian curve to include the side bands and to reduce the concentrationof the electromagnetic flux at the position of the coupler coil CC (i.e.to avoid overpowering the RFID chip). This may improve the communicationof signals carried between the RFID device (secure document orsmartcard) and the reader on the sub-carrier frequencies (thesub-carrier frequencies is typically +/−848 kHz at 12.712 MHz and 14.408MHz for a device operating at 13.56 MHz, as per ISO/IES 14443-2).

The metal foil or metallic structure can advantageously alter (such aslower) the quality factor (Q) of the booster antenna (BA). The metalfoil or metallic structure can also have a capacitive effect in thecircuit. The presence of the metal foil or metallic structure in thecard design can alter the electrical power delivered to the IC chip(CM). Some or all of these effects may enhance the performance of theRFID device or smartcard, improving the coupling between the antennamodule AM and the coupler coil CC of the booster antenna BA. Thecommunication between the RFID device or smartcard and the reader canthus be improved.

The metal foil MF together with the booster antenna BA generatescapacitance in the resonant circuit which may result in a broadening ofthe resonance curve and which may improve signal communication on thesub-carrier frequencies, typically at 12.712 MHz and 14.408 MHz (i.e.+/−848 kHz for a device operating at 13.56 MHz).

A metal foil, metal coating or metal particles can be implemented in theRFID device or smartcard in a number of ways as described hereunder. Avery thin continuous metal foil can be deposited directly on top of thebooster inlay (card body CB), behind the booster inlay or within thebooster inlay structure. The metal foil can be supported on a plasticsubstrate, such as Poly(ethylene terephthalate) (PET), before beingincorporated into the booster antenna structure.

FIG. 14C-F shows methods of applying conductive material in the cardbody CB, which may reduce the Quality factor (Q) of the coupler coil CCto include sidebands and improve coupling between the coupler coil CCand the module antenna MA.

FIG. 14C illustrates a booster antenna (BA) placed on a transparent PVCsubstrate that has been laminated to a second PVC layer bearing a metalfoil coating. The metal foil may have a thickness typically of the orderof tens of nanometers (for example 15 nm). The thickness of the metalfoil dictates the effect on the electrical properties of the RFID deviceor smartcard. The metal foil can deposited anywhere within the body ofthe card and may have a size matching the full area of the card body CB,or only a portion thereof. The foil can also be used to overlap only thebooster antenna or parts of the booster antenna. Multiple areas of foilscan be deposited within the card body to alter the performance effect.Additionally, multiple layers of foils can be deposited within a cardbody. The metal foil can be disposed on the PCV substrate without theintermediary of the second PVC layer.

As an alternative to a continuous metal foil, a perforated (or otherwisesegmented or discontinuous) metal foil can be used. The perforations mayallow the electromagnetic flux from the RFID reader to substantiallypenetrate the card body (CB). The perforated foil can be depositedanywhere within the card body, as described above. The thickness of aperforated foil may be greater than the thin continuous foils describedabove—for example, greater than 15 nm (A continuous metal foil may havea thickness less than 15 nm)

As an alternative to a continuous metal foil, a metal mesh can be used.The mesh can be deposited anywhere within the card body as describedabove. The metal mesh can also be constructed of a porous network

Metal particles of various sizes and shapes (including spheres andflakes) can be deposited on the surface of the booster antenna (BA) oran additional inlay layer within the card body. The metal particles canbe formed a range of materials including metal alloys and can bedeposited within the material used to form the inlay or other layerswithin the card body. The metal particles can also be derived from aconventional metallic finish on the surface of the card.

The metal foil MF or metallic structure can cover the full area of theRFID device or smartcard as illustrated in FIG. 14C or can partiallycover the area leaving selectively exposed regions.

FIG. 14D illustrates an embodiment of the invention where the area ofthe coupling coil (or coupling loop) is left free of the metal foil. Themetal foil MF or metallic structure partially covers the smartcard area,leaving exposed metal-free region at the coupling loop of the boosterantenna (BA). This may substantially reduce (or prevent) attenuation ofthe inductive coupling between the coupler coil CC and the moduleantenna MA (not shown). This is illustrative of a metal foil or metallicstructure partially covering the smartcard area, leaving an exposedmetal-free region at the location of the coupling coil CC of the boosterantenna (BA). The recess of (opening in) the metallized foil MF at thelocation of the chip module (underneath the coupling loop) may help toreduce the quality (Q) of the booster antenna without having destructiveeffects on the coupling between the booster antenna BA and the antennamodule AM.

FIG. 14E illustrates a continuous metal loop or loop of a metallicstructure is disposed on top of or below the booster antenna BA, and maycover part of the booster antenna BA.

FIG. 14F illustrates a discontinuous (broken) metal loop or loop of ametallic structure is placed on top of or below the booster antenna, andmay cover part of the booster antenna BA. In this case, the ends of theopen loop may be left open or connected to a resistive load.

Alternatively, a resistor can be formed by narrowing a section of themetal loop or metallic structure in order to locally reduce the crosssectional area of the loop.

The metal foils may comprise a conductive material (such as aluminum onPVC), having a sheet resistance which is very low, on the order of onlya few Ohms, which normally should block the electromagnetic field (suchas between the booster antenna BA and an external reader, or between thebooster antenna BA and the antenna module AM), but a mitigating factormay be the thickness of the aluminum (or other material), being thinenough to allow the electromagnetic field to pass through.

Metal foils or substrate materials having metallized coatings may beused in the production of the booster antenna (BA) for RFID devices orsmartcards. The metal can be any pure metal such as aluminum or copperor an alloy. Other electrical conductors such as metal nanoparticles,metal nanowires or carbon-based conductors like graphite or exfoliatedgraphite may also be used.

The booster antenna (BA) is normally constructed from a track of wireembedded in an inlay substrate comprising one or more layers of amaterial such as Polyvinyl Chloride (PVC), Polycarbonate (PC),Polyethylene (PE), Poly(ethylene terephthalate) (PET),Polyetherurethane, PET-G (Polyethylene Terephtalate Glycol-modified),Polyester Copolymer film, Teslin™, paper, synthetic paper and the like.Alternatively the booster antenna (BA) can be formed on the inlaysubstrate by chemically or laser etching a metal coating previouslydeposited on the substrate. A particular design of booster antenna (BA)with coupler coil (CC), having a certain geometry and number of coilwindings, will exhibit specific electrical characteristics in terms ofsay resonance frequency and impedance. Metal foils, metallic coatings,segments of metal foil or metal particles may be deposited on orembedded in the inlay substrate or card body to alter the electricalcharacteristics of the RFID device or smartcard.

The effect of the metal or metallic structures can be to dampen thebooster antenna (BA) resulting in a widening of the resonance curve ofthe booster antenna (BA) and lowering the quality factor (Q). The metalor metallic structure can also have a capacitive effect in the circuit.These effects can enhance the performance of the RFID device orsmartcard. The communication between the RFID device or smartcard andthe reader can thus be improved.

The metal foil, metal coating or metal particles can be implemented inthe device in a number of ways, for example, but not limited to:

-   -   (a) A very thin metal continuous metal foil can be deposited on        the booster inlay or within the booster inlay. The metal can        thin (less than 10 micron in thickness for example) or extremely        thin (or the order of nanometers). The metal foil can deposited        anywhere within the body of the card and may have size matching        the full area of the card of part of the card. The foil can also        be used to overlap only the booster antenna or parts of the        booster antenna.    -   (b) A perforated metal foil can be used. The perforations allow        the electromagnetic flux from the RFID reader to largely        penetrate the card. The perforated foil can be deposited        anywhere within the card as described in 1 above.    -   (c) A metal mesh can be used. The mesh can be deposited anywhere        within the card as described in (a).

Metal particles of various sizes and shapes (including spheres andflakes) can be deposited on the surface of the booster antenna (BA) oran additional inlay within the card body. The metal particles can beformed a range of materials including metal alloys and can be depositedwithin the material used to form the inlay or other layers within thecard body. The metal particles can also be derived from a conventionalmetallic finish on the surface of the card.

According to some embodiments (examples) of the invention, a card body(CB) for a smart card (SC) may comprise: a metal foil (MF) layerincorporated into the card body (CB); and may be

characterized in that: the metal foil (MF) comprises a material selectedfrom the group consisting of pure metals, alloys, aluminum, copper,metal nanoparticles, metal nanowires, carbon-based conductors, graphite,and exfoliated graphite; and the metal foil may be characterized by oneor more of: the metal foil comprises a very thin continuous layerdeposited on the card body (CB); the metal foil has a size matching anarea of the card body (CB), or only a portion thereof; the metal foiloverlaps only the booster antenna (BA) or portions or components of thebooster antenna; the metal foil comprises multiple areas of foils whichare deposited on or in the card body (CB); the metal foil is perforated,segmented or discontinuous; the metal foil is continuous, and has athickness less than 15 nm; the metal foil is discontinuous, and has athickness greater than 15 nm; the metal foil comprises a mesh; the metalfoil comprises metal particles of various sizes and shapes; the metalfoil partially covers the smartcard area, leaving exposed metal-freeregion at a coupling coil (CC) of the booster antenna (BA); the metalfoil reduces the quality (Q) of the booster antenna without havingdestructive effects on the coupling between the booster antenna (BA) andthe antenna module (AM); the metal foil comprises (FIG. 22F) acontinuous loop; the metal foil comprises (FIG. 22G) a discontinuousloop; the metal foil comprises a resistor formed by narrowing a sectionof a metal loop; and the metal foil comprises a conductive materialhaving a sheet resistance on the order of only a few Ohms. The metalfoil may be characterized by at least one of: the metal foil iscontinuous, and has a thickness of less than 10 μm; the metal foil isperforated; the metal foil comprises a mesh; and the metal foilcomprises metal particles.

Some Additional Embodiments

In a manner analogous to how having a booster antenna (BA, moreparticularly the card antenna CA component thereof) with two windingsconnected in a quasi-dipole (“Q-D”) configuration may be applied to themodule antenna (MA), as described with respect to FIG. 9D (and 9C), theconcept of having a module antenna (MA) comprising a antenna segment(“A”) with capacitive stubs (“B” and “C”), as in described with respectto FIG. 9A (and 9B), may be applied to booster antennas (BA). See alsoFIG. 2A of U.S. Ser. No. 13/205,600 filed 8 Aug. 2011 (now U.S. Pat. No.8,474,726 issued 2013 Jul. 12; “S34”)

FIG. 15 shows (schematically) an embodiment of a booster antenna BAhaving an antenna component 1510 (compare “A” in FIG. 9A), which may beany one (or more) of the card antenna CA, coupler coil CC or extensionantenna EA components. Here, the antenna component 1510 is shown ashaving two ends “1” and “2”, which are not free ends, but it is withinthe scope of the invention that the antenna component 1510 has only onefree end, or no free ends.

A first stub (or extension CE) component 1512 (compare “B” in FIG. 9A)may be connected (in any suitable manner, as represented by the blackdot) by an end “4 to the end “1” of the antenna component 1510, and mayhave another end “3” which is left unconnected (as a free end). A secondstub (or extension CE) component 1514 (compare “C” in FIG. 9A) may beconnected (in any suitable manner, as represented by the black dot) byan end “5 to the end “2” of the antenna component 1510, and may haveanother end “6” which is left unconnected (as a free end). The stubcomponents 1512 and 1514 may constitute capacitive extensions of theantenna component 1510, such as has been described in U.S. Ser. No.13/205,600 filed 8 Aug. 2011 (now U.S. Pat. No. 8,474,726 issued 2013Jul. 12; “S34”), with respect to a module antenna in an antenna module.This may include that there are two capacitive stubs and they are formedin a flat coil pattern having a number of turns, and are substantiallyidentical with one another.

FIG. 15A shows a more realistic representation of a booster antenna BAhaving a card antenna CA component, a coupler coil CC component, and twocapacitive extension components 1512 and 1514. One capacitive extensionCE component 1512 extends from an end of the card antenna CA component.The other capacitive extension CE component 1514 extends from an end ofthe coupler coil CC component. This illustrates that the capacitiveextension CE components may extend from different components (CA, CC,EA) of the booster antenna BA. (Any of the components illustrated mayhave two (or more windings), but are shown with a single winding, forillustrative clarity. The extension antenna EA component has beenomitted, for illustrative clarity, but may be one of the booster antennaBA components provided with one or more capacitive extensions, anditself may be arranged to serve as a capacitive extension CE.)

FIG. 15B shows an embodiment of a booster antenna BA having a cardantenna CA component, a coupler coil CC component, and an extensionantenna EA component. In this example, the extension antenna EAcomponent is shown having inner and outer windings. Compare FIG. 4Iwhich shows two extension antennas EA-1 and EA2. This illustrates that agiven component (CA, CC, EA) of a booster antenna BA may have two ormore windings which may be, but need not necessarily be arranged asinner and outer (IW/OW, iw/ow, IP/OP) windings. And, although thebooster antenna BA in this example is shown without and free ends, itshould be understood that any of the components (CA, CC, EA, as well asCE) may have at least one free end.

It may also be noted that FIG. 6A shows one of the free ends (“f”) beingin the extension antenna EA component, the other free end “a” being inthe coupler coil CC component (in this embodiment, there is no showingof a card antenna CA component, and the booster antenna BA is showndisposed in the top half of the card body). And, that FIG. 6B shows bothof the free ends “a” and “f” disposed in the extension antenna EAcomponent (in this embodiment, there is no showing of a card antenna CAcomponent, and the booster antenna BA is shown disposed in the top halfof the card body). FIG. 5D shows that two free ends of the boosterantenna BA may be in the coupler coil CC component (in theseembodiments, there is no showing of an extension antenna EA component).FIG. 2 shows that two free ends of the booster antenna BA may be in thecard antenna CA component.

This is illustrative of the proposition that selected features ofvarious embodiments disclosed herein may be incorporated with otherembodiments, to arrive at a desired configuration for the boosterantenna BA. This would include, but is not limited to (i) having two ormore windings per component, (ii) a component having one or more freeends, as well as (iii) the particular sense (CW, CCW) of a component orportions thereof, and (iv) any other features that are disclosed herein.

FIG. 15C shows a portion of a booster antenna BA wherein two components(any of CA, CC, EA, CE) or two windings of a single component, orportions thereof, may be laid so that their turns are interleaved withone another—herein labeled as “component/winding #1” and“component/winding #2”.

FIG. 15D shows a portion of a booster antenna BA wherein at least onecomponent (any of CA, CC, EA, CE), or portions thereof, may be laid sothat several of its/their turns cross over each other, multiple times.Here, one of the components “component/winding #1” is shown with atleast portions of some of its turns laid horizontally (fromleft-to-right, as viewed) on the card body (CB, not shown), and theother of the components “component/winding #2” is shown with at leastportions of some of its turns laid vertically (from top-to-bottom, asviewed) on the card body (CB).

While the invention(s) has/have been described with respect to a limitednumber of embodiments, these should not be construed as limitations onthe scope of the invention(s), but rather as examples of some of theembodiments. Those skilled in the art may envision other possiblevariations, modifications, and implementations that are also within thescope of the invention(s), based on the disclosure(s) set forth herein.

What is claimed is:
 1. Booster antenna (BA) comprising the following components: a card antenna (CA) component; a coupler coil (CC) component; and an extension antenna (EA) component; characterized in that: at least one of the components has a pitch which is different than one or more of the other components.
 2. The booster antenna (BA) of claim 1, wherein: the card antenna (CA) component has an outer winding (OW) and an inner winding (IW).
 3. The booster antenna (BA) of claim 1, wherein: the pitch of the outer and inner windings are substantially the same as one another.
 4. The booster antenna (BA) of claim 1, wherein: the pitch of the outer and inner windings are different than one another.
 5. The booster antenna (BA) of claim 1, wherein: at least one of the components comprises an outer winding (OW, ow) and an inner winding (IW, iw).
 6. The booster antenna (BA) of claim 1, wherein: the card antenna component has a pitch of approximately 200μm.
 7. The booster antenna (BA) of claim 1, wherein: the coupler coil (CC) component has a pitch of approximately 150μm.
 8. The booster antenna (BA) of claim 1, wherein: the booster antenna comprises wire having a diameter; and the pitch of at least one of the components is approximately 2×(twice) the diameter of the wire, resulting in a spacing between adjacent turns of components on the order of 1 wire diameter.
 9. The booster antenna (BA) of claim 1, wherein: the coupler coil (CC) and extension antenna (EA) components are combined with one another, as a coil, wherein the turns increase in pitch as the combined CC/EA booster antenna component extends across an area of a card body (CB) of a smart card (SC).
 10. The booster antenna (BA) of claim 1, wherein: the extension antenna (EA) component varies as it extends across an area of a card body (CB) of a smart card (SC).
 11. The booster antenna (BA) of claim 1, wherein: the pitch of the extension antenna (EA) component is different than the pitch of the coupler coil (CC) component.
 12. The booster antenna (BA) of claim 1, wherein: at least one of the extension antenna (EA) and coupler coil (CC) components have pitches different than that of the card antenna (CA) component.
 13. A smart card (SC) incorporating the booster antenna (BA) of claim
 1. 14. The booster antenna (BA) of claim 1, wherein: the extension antenna (EA) component lowers the resonance frequency of the booster antenna BA to a desired resonance.
 15. The booster antenna (BA) of claim 1, wherein: the pitch of individual turns of the extension antenna (EA) are adjusted to match the booster antenna (BA) resonance frequency.
 16. The booster antenna (BA) of claim 1, wherein: the extension antenna (EA) concentrates the electromagnetic field when in close coupling proximity to an external contactless reader.
 17. The booster antenna (BA) of claim 1, further comprising: at least one additional extension antenna (EA) component. 